Selective and Mild Oxyfunctionalization of Model Polyolefins

Catalytic Upcycling of Polyolefins

The large production volumes of commodity polyolefins (specifically, polyethylene, polypropylene, polystyrene, and poly(vinyl chloride)), in conjunction with their low unit values and multitude of short-term uses, have resulted in a significant and pressing waste management challenge. Only a small fraction of these polyolefins is currently mechanically recycled, with the rest being incinerated, accumulating in landfills, or leaking into the natural environment. Since polyolefins are energy-rich materials, there is considerable interest in recouping some of their chemical value while simultaneously motivating more responsible end-of-life management. An emerging strategy is catalytic depolymerization, in which a portion of the C-C bonds in the polyolefin backbone is broken with the assistance of a catalyst and, in some cases, additional small molecule reagents. When the products are small molecules or materials with higher value in their own right, or as chemical feedstocks, the process is called upcycling. This review summarizes recent progress for four major catalytic upcycling strategies: hydrogenolysis, (hydro)cracking, tandem processes involving metathesis, and selective oxidation. Key considerations include macromolecular reaction mechanisms relative to small molecule mechanisms, catalyst design for macromolecular transformations, and the effect of process conditions on product selectivity. Metrics for describing polyolefin upcycling are critically evaluated, and an outlook for future advances is described.

Engineered Anchor Peptide LCI with a Cobalt Cofactor Enhances Oxidation Efficiency of Polystyrene Microparticles

A typical component of polymer waste is polystyrene (PS) used in numerous applications, but degraded only slowly in the environment due to its hydrophobic properties. To increase the reactivity of polystyrene, polar groups need to be introduced. Here, biohybrid catalysts based on the engineered anchor peptide LCI_F16C are presented, which are capable of attaching to polystyrene microparticles and hydroxylating benzylic C-H bonds in polystyrene microparticles using commercially available oxone as oxidant. LCI peptides achieve a dense surface coverage of PS through monolayer formation within minutes in aqueous solutions at ambient temperature. The catalytically active cobalt cofactor Co-L1 or Co-L2 with a modified NNNN macrocyclic TACD ligand (TACD=1,4,7,10-tetraazacyclododecane) is covalently bound to the anchor peptide LCI through a maleimide linker. Compared to the free cofactors, a 12- to 15-fold improvement in catalytic activity using biohybrid catalysts based on LCI_F16C was observed.

Chemically Recyclable Linear and Branched Polyethylenes Synthesized from Stoichiometrically Self-Balanced Telechelic Polyethylenes

High-density polyethylene (HDPE) is a widely used commercial plastic due to its excellent mechanical properties, chemical resistance, and water vapor barrier properties. However, less than 10% of HDPE is mechanically recycled, and the chemical recycling of HDPE is challenging due to the inherent strength of the carbon-carbon backbone bonds. Here, we report chemically recyclable linear and branched HDPE with sparse backbone ester groups synthesized from the transesterification of telechelic polyethylene macromonomers. Stoichiometrically self-balanced telechelic polyethylenes underwent transesterification polymerization to produce the PE-ester samples with high number-average molar masses of up to 111 kg/mol. Moreover, the transesterification polymerization of the telechelic polyethylenes and the multifunctional diethyl 5-(hydroxymethyl)isophthalate generated branched PE-esters. Thermal and mechanical properties of the PE-esters were comparable to those of commercial HDPE and tunable through control of the ester content in the backbone. In addition, branched PE-esters showed higher levels of melt strain hardening compared with linear versions. The PE-ester was depolymerized into telechelic macromonomers through straightforward methanolysis, and the resulting macromonomers could be effectively repolymerized to generate a high molar mass recycled PE-ester sample. This is a new and promising method for synthesizing and recycling high-molar-mass linear and branched PE-esters, which are competitive with HDPE and have easily tailorable properties.

Diverse functional polyethylenes by catalytic amination

Functional polyethylenes possess valuable bulk and surface properties, but the limits of current synthetic methods narrow the range of accessible materials and prevent many envisioned applications. Instead, these materials are often used in composite films that are challenging to recycle. We report a Cu-catalyzed amination of polyethylenes to form mono- and bifunctional materials containing a series of polar groups and substituents. Designed catalysts with hydrophobic moieties enable the amination of linear and branched polyethylenes without chain scission or cross-linking, leading to polyethylenes with otherwise inaccessible combinations of functional groups and architectures. The resulting materials possess tunable bulk and surface properties, including toughness, adhesion to metal, paintability, and water solubility, which could unlock applications for functional polyethylenes and reduce the need for complex composites.

Polymer up-cycling by mangana-electrocatalytic C(sp3)-H azidation without directing groups

The chemical up-cycling of polymers into value-added materials offers a unique opportunity to place plastic waste in a new value chain towards a circular economy. Herein, we report the selective up-cycling of polystyrenes and polyolefins to C(sp3)-H azidated materials under electrocatalytic conditions. The functionalized polymers were obtained with high retention of mass average molecular mass and high functionalization through chemo-selective mangana-electrocatalysis. Our strategy proved to be broadly applicable to a variety of homo- and copolymers. Polyethylene, polypropylene as well as post-consumer polystyrene materials were functionalized by this approach, thereby avoiding the use of hypervalent-iodine reagents in stoichiometric quantities by means of electrocatalysis. This study, hence, represents a chemical oxidant-free polymer functionalization by electro-oxidation. The electrocatalysis proved to be scalable, which highlights its unique feature for a green hydrogen economy by means of the hydrogen evolution reaction (HER).

Zirconium-Catalyzed C-H Alumination of Polyolefins, Paraffins, and Methane

C-H/Et-Al exchange in zirconium-catalyzed reactions of saturated hydrocarbons and AlEt₃ affords versatile organoaluminum compounds and ethane. The grafting of commercially available Zr(OtBu)₄ on silica/alumina gives monopodal ≡SiO-Zr(OtBu)₃ surface pre-catalyst sites that are activated in situ by ligand exchange with AlEt₃. The catalytic C-H alumination of dodecane at 150 °C followed by quenching in air affords n-dodecanol as the major product, revealing selectivity for methyl group activation. Shorter hydrocarbon or alcohol products were not detected under these conditions. Catalytic reactions of cyclooctane and AlEt₃, however, afford ring-opened products, indicating that C-C bond cleavage occurs readily in methyl group-free reactants. This selectivity for methyl group alumination enables the C-H alumination of polyethylenes, polypropylene, polystyrene, and poly-α-olefin oils without significant chain deconstruction. In addition, the smallest hydrocarbon, methane, undergoes selective mono-alumination under solvent-free catalytic conditions, providing a direct route to Al-Me species.

Polyolefin Innovations toward Circularity and Sustainable Alternatives

The unprecedented growth and socioeconomic impacts of polyolefins clearly outline a major success story in the world of polymer science. Polyolefins revolutionizes industries such as health care, construction, and food packaging. Despite the benefits of polyolefins, there is a rising concern for the environment due to high production volume (i.e., fossil fuel consumption), often short usage time, and problems related to waste management and accumulation in the natural environment. Creating a circular economy for polyolefins through effective recycling technologies has the potential to decrease the environmental impact of these materials. This perspective discusses polyolefins and their impact, existing and emerging recycling/upcycling solutions, and recycle-by-design alternatives that are challenging the status quo.

Tandem ROMP/Hydrogenation Approach to Hydroxy-Telechelic Linear Polyethylene

Hydroxy-telechelic polyalkenamers have long been synthesized using ring-opening metathesis polymerization (ROMP) in the presence of an acyclic olefin chain-transfer agent (CTA); however, this route typically requires protected diols in the CTA due to the challenge of alcohol-mediated degradation of ruthenium metathesis catalysts that can not only deactivate the catalysts, but also compromise the CTA. We demonstrate the synthesis and implementation of a new hydroxyl-containing CTA in which extended methylene spacers isolate the olefin and alcohol moieties to mitigate decomposition pathways. This CTA enabled the direct ROMP synthesis of hydroxy-telechelic polycyclooctene with controlled chain lengths dictated by the initial ratio of monomer to CTA. The elimination of protection/deprotection steps resulted in improved atom economy. Subsequent hydrogenation of the backbone olefins was performed by a one-pot, catalytic approach employing the ruthenium complex used for the initial ROMP. The resultant approach is a streamlined, atom-economic, and low-waste route to hydroxy-telechelic linear polyethylene that uses a green solvent, succeeds with miniscule quantities of catalyst (0.005 mol %), and requires no additional purification steps.

Exhaustive Baeyer–Villiger oxidation: a tailor-made post-polymerization modification to access challenging poly(vinyl acetate) copolymers

The discovery of exhaustive (nearly quantitative) post-polymerization modifications (PPM) relies heavily on the efficiency of their corresponding small-molecule protocols. However, the direct translation of existing small-molecule protocols into PPM methods has never been guaranteed due to the intrinsic differences between small-molecule substrates and polymers. Herein, we introduce the direct optimization on polymers (DOP) as a complementary approach to developing exhaustive PPM reactions. As proof of the DOP concept, we present an exhaustive Baeyer–Villiger (BV) post-modification which cannot be accessed by conventional approaches. This user-friendly methodology provides general access to synthetically challenging copolymers of vinyl acetate and more activated monomers (MAMs) including both statistical and narrow-dispersed block copolymers. Furthermore, a scalable one-pot copolymerization/exhaustive BV post-modification procedure was developed to produce such materials showing improved performance over regular PVAc.

Exhaustive Baeyer–Villiger (BV) oxidation, which was developed by a direct optimization on polymers (DOP) approach, provides a general solution for preparing synthetically challenging poly(vinyl acetate) statistical and block copolymers.

Ruthenium-Catalyzed, Chemoselective and Regioselective Oxidation of Polyisobutene

Polyolefins are important commodity plastics, yet their lack of functional groups limits their applications. The functionalization of C-H bonds holds promise for incorporating functionalities into polymers of ethylene and linear α-olefins. However, the selective functionalization of polyolefins derived from branched alkenes, even monobranched, 1,1-substituted alkenes, has not been achieved. These polymers are less reactive, due to steric effects, and they are prone to chain scission that degrades the polymer. We report the chemoselective and regioselective oxidation of a commercially important polymer of a branched olefin, polyisobutene. A polyfluorinated ruthenium-porphyrin catalyst incorporates ketone units into polyisobutene at methylene positions without chain cleavage. The oxidized polymer is thermally stable, yet it undergoes programmed reactions and possesses enhanced wetting properties.

The post-modification of polyolefins with emerging synthetic methods

This Perspective highlights the present state of polyolefin post-modification research, especially concerning recently developed C–H functionalization chemistry. Remaining challenges and emerging strategies within the field have also been discussed.

Chemo- and Regioselective Functionalization of Isotactic Polypropylene: A Mechanistic and Structure-Property Study

Polyolefins represent a high-volume class of polymers prized for their attractive thermomechanical properties, but the lack of chemical functionality on polyolefins makes them inadequate for many high-performance engineering applications. We report a metal-free postpolymerization modification approach to impart functionality onto branched polyolefins without the deleterious chain-coupling or chain-scission side reactions inherent to previous methods. The identification of conditions for thermally initiated polyolefin C-H functionalization combined with the development of new reagents enabled the addition of xanthates, trithiocarbonates, and dithiocarbamates to a variety of commercially available branched polyolefins. Systematic experimental and kinetic studies led to a mechanistic hypothesis that facilitated the rational design of reagents and reaction conditions for the thermally initiated C-H xanthylation of isotactic polypropylene (iPP) within a twin-screw extruder. A structure-property study showed that the functionalized iPP adheres to polar surfaces twice as strongly as commercial iPP while demonstrating similar tensile properties. The fundamental understanding of the elementary steps in amidyl radical-mediated polyolefin functionalization provided herein reveals key structure-reactivity relationships for the design of improved reagents, while the demonstration of chemoselective and scalable iPP functionalization to realize a material with improved adhesion properties indicates the translational potential of this method.

A direct functionalization of polyolefins for blend compatibilization by an insertion of 1,1-bis(phenylsulfonyl)ethylene (BPSE)

A mild post-modification of polyethylene (PE) & polypropylene (PP) to insert phenylsulfonyl groups is reported, the modified samples demonstrated to act as blend compatibilizers.

A recyclable hybrid manganese(III) porphyrin magnetic catalyst for selective olefin epoxidation using molecular oxygen

The synthesis and characterization of a hybrid Mn(III)-porphyrin magnetic nanocomposite is described. Moreover, a sustainable methodology for epoxidation of olefins is reported, using O[Formula: see text] as a green oxidant and the magnetic nanoparticle as a recyclable catalyst. High activity in alkene oxidation was observed, with full selectivity for epoxide formation. The magnetic catalyst presented high stability, being recovered and reused in five consecutive runs without loss of catalytic activity or selectivity in cyclooctene oxidation. Moreover, the catalytic system showed very good reactivity toward epoxidation of a range of terminal, substituted, cyclic or acyclic, aliphatic and aromatic olefins, including terpene and steroid derivatives, affording a range of biologically relevant epoxides in excellent yields. The isobutyric acid, formed as side-product, was recovered with high yield and purity, which provides the potential reutilization of this important industrial product.

Catalytic Hydroxylation of Polyethylenes

Polyolefins account for 60% of global plastic consumption, but many potential applications of polyolefins require that their properties, such as compatibility with polar polymers, adhesion, gas permeability, and surface wetting, be improved. A strategy to overcome these deficiencies would involve the introduction of polar functionalities onto the polymer chain. Here, we describe the Ni-catalyzed hydroxylation of polyethylenes (LDPE, HDPE, and LLDPE) in the presence of ^m CPBA as an oxidant. Studies with cycloalkanes and pure, long-chain alkanes were conducted to assess precisely the selectivity of the reaction and the degree to which potential C-C bond cleavage of a radical intermediate occurs. Among the nickel catalysts we tested, [Ni(Me₄Phen)₃](BPh₄)₂ (Me₄Phen = 3,4,7,8,-tetramethyl-1,10-phenanthroline) reacted with the highest turnover number (TON) for hydroxylation of cyclohexane and the highest selectivity for the formation of cyclohexanol over cyclohexanone (TON, 5560; cyclohexanol/(cyclohexanone + ε-caprolactone) ratio, 10.5). The oxidation of n-octadecane occurred at the secondary C-H bonds with 15.5:1 selectivity for formation of an alcohol over a ketone and 660 TON. Consistent with these data, the hydroxylation of various polyethylene materials by the combination of [Ni(Me₄Phen)₃](BPh₄)₂ and ^m CPBA led to the introduction of 2.0 to 5.5 functional groups (alcohol, ketone, alkyl chloride) per 100 monomer units with up to 88% selectivity for formation of alcohols over ketones or chloride. In contrast to more classical radical functionalizations of polyethylene, this catalytic process occurred without significant modification of the molecular weight of the polymer that would result from chain cleavage or cross-linking. Thus, the resulting materials are new compositions in which hydroxyl groups are located along the main chain of commercial, high molecular weight LDPE, HDPE, and LLDPE materials. These hydroxylated polyethylenes have improved wetting properties and serve as macroinitiators to synthesize graft polycaprolactones that compatibilize polyethylene-polycaprolactone blends.

On the synthesis of functionalized porphyrins and porphyrin conjugates via β-aminoporphyrins

A two-step methodology to prepare a series ofmeso-tetraarylporphyrin conjugates bearing water-soluble moieties, anchoring groups and receptor subunits.

Catalytic hydroxylation of polypropylenes

The regioselective functionalization of both model and commercial polypropylenes of varying tacticity has been conducted by a rhodium-catalyzed functionalization of the methyl C-H bonds of the polymer with diboron reagents. Rhodium-catalyzed borylation of the polypropylenes, followed by oxidation of the boron-containing material, produced polymers containing 0.2-1.5% hydroxymethyl side chains. Both the number-average molecular weights and molecular weight distributions of the polypropylenes were essentially unchanged after the catalytic and oxidative functionalization process. The efficiency of the borylation process was affected by the molecular weight of the polymer, the steric hindrance around the methyl groups, and the ratio of the diboron reagent to the monomer repeat unit. The hydroxylated derivative of the commercial isotactic polypropylene was used as macroinitiator for the aluminum-mediated ring-opening polymerization of epsilon-caprolactone to prepare polypropylene-graft-polycaprolactone. This graft copolymer was an effective compatibilizer for melt blends of polypropylene and polycaprolactone.

Dehydrogenation of aliphatic polyolefins catalyzed by pincer-ligated iridium complexes

We report the first example of the catalytic dehydrogenation of aliphatic polyolefins to give partially unsaturated hydrocarbon polymers.