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experimental data continue to be obtained, and certain mechanistic concepts are being developed with the use of outdated models.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

Real-time Analysis of a Working Triethylaluminium-Modified Cr/Ti/SiO2 Ethylene Polymerization Catalyst with In Situ Infrared Spectroscopy

A diffuse reflectance infrared Fourier-transform (DRIFT) study has been conducted at 373 K and 1 bar on an industrial Cr/Ti/SiO2 Phillips-type catalyst modified with, and without, triethylaluminium (TEAl) as co-catalyst. The reaction rate of the polymerization of ethylene, as monitored by the increase in the methylene stretching band of the growing polyethylene (PE), has been investigated as a function of the titanium content. After an initial period of mixed kinetics, with the reaction rate significantly higher for the TEAl-modified catalysts compared with the non-modified catalysts, the polymerization proceeded as a pseudo-zero-order reaction with a reaction rate that increased as a function of titanium loading. Furthermore, it was found that the higher Ti loading caused the appearance of more acidic hydroxyl groups and modified the Cr sites by making them more Lewis acidic, ultimately shortening the induction time and increasing the initial polymerization rate.

Surface chromium single sites: open problems and recent advances

The results of decades of studies on the Phillips chromium (Cr)/silica polymerization catalyst are briefly summarized. The application of several characterization methods has allowed a detailed knowledge of the structure and reactivity of Cr centres to be obtained. In particular, many aspects of this apparently simple single-site catalyst, including the heterogeneity, the modification of the ligand sphere upon interaction with many molecules and the initiation mechanism of the ethylene polymerization reaction, have been clarified. It is shown that based on the acquired knowledge, it is now possible to proceed further towards the intelligent modification of the ligand sphere with the scope to increase the reaction rate and selectivity. It is also illustrated that, besides polymerization/oligomerization reactions, it is possible to extend the study of Cr II reactivity towards new reactions.