Rapid evaluation of catalysts and MAO activators by kinetics: what controls polymer molecular weight and activity in metallocene/MAO catalysts?

Sheet Models for Methylaluminoxane (MAO) Activators? A Theoretical Case Study involving rac-Me2Si(η5-C9H6)2Zr (SBIZr) Complexes

Activation of SBIZrMe2 or SBIZrMeCl and a sheet model for an active component of hydrolytic MAO, (MeAlO)16(Me3Al)6, (16,6) has been studied by DFT. Contact ion-pair formation occurs through the intermediacy of SBIZrMe(Cl) or SBIZrMe2 reacting with sheet 16,6 to furnish SBIZrMe-μ-X(MeAlO)16(Me3Al)6 (2, X=Me, Cl). Contact ion-pairs 2 would be in equilibrium with heterodinuclear catalyst precursors [SBIZrMe2AlMe2][(MeAlO)16(Me3Al)6X] (3 (X=Me, Cl) through reversible binding of Me3Al at higher Al : Zr ratios. Calculations show that formation of ion-pairs 3 from contact ion-pairs 2 is more favourable for the SBIZr compared with the parent Cp2Zr complexes. TD-DFT calculations were conducted on relevant SBIZr complexes to relate the results to earlier spectroscopic studies of catalyst activation using UV-Vis spectroscopy. Finally, propene insertion into ion-pairs 2, SBIZrMe-μ-MeB(C6F5)3 (6) and [SBIZrMe][B(C6F5)4] (7) was studied at M06-2X/TZVP level of theory. These studies suggest that contact ion-pairs 2 are significantly less reactive towards insertion than 6 or 7, in disagreement with experiment.

A High-Throughput Approach to Repurposing Olefin Polymerization Catalysts for Polymer Upcycling

Efficient and economical plastic waste upcycling relies on the development of catalysts capable of polymer degradation. A systematic high-throughput screening of twenty-eight polymerization catalyst precursors, belonging to the catalyst families of metallocenes, ansa-metallocenes, and hemi- and post-metallocenes, in cis-1,4-polybutadiene (PB) degradation reveals, for the first time, important structure-activity correlations. The upcycling conditions involve activation of the catalysts (at 0.18 % catalyst loading) with tri-iso-butyl aluminum at 50 °C in toluene. The data indicate the ability to degrade PB is a general reactivity profile of neutral group 4 metal hydrides. A simple quantitative-structure activity relationship (QSAR) model utilizing two descriptors for the distribution of steric bulk in the active pocket and one measuring the metal ion electrophilicity reveals the degradation ability improves with increased but not overbearing steric congestion and lower electrophilicity.

Methods for Predicting Ethylene/Cyclic Olefin Copolymerization Rates Promoted by Single-Site Metallocene: Kinetics Is the Key

In toluene at 50 °C, the vinyl addition polymerization of 4-vinyl-cyclohexene (VCH) comonomers with ethylene is investigated using symmetrical metallocene (rac-Et(Ind)₂ZrCl₂) combined with borate/TIBA. To demonstrate the polymerizations’ living character, cyclic VCH with linear-exocyclic_π and endocyclic_π bonds produces monomodal polymers, but the dispersity (Ɖ) was broader. The copolymers obtained can be dissolved in conventional organic solvent and have excellent thermal stability and crystalline temperature (ΔH_m), and their melting temperature (Tm) varies from 109 to 126 °C, and ΔH_m ranges from 80 to 128 (J/g). Secondly, the distribution of polymeric catalysts engaged in polymer chain synthesis and the nature of the dormant state are two of the most essential yet fundamentally unknown aspects. Comprehensive and exhaustive kinetics of E/VCH have shown numerous different kinetic aspects that are interpreted as manifestations of polymeric catalysts or of the instability of several types of active center [Zr]/[C*] fluctuations and formation rates of chain propagation R_pE, R_pVCH, and propagation rate constants k_pE and k_pVCH, the quantitative relationship between R_pE, R_pVCH and k_pE, k_pVCH and catalyst structures, their constituent polymer Mw, and their reactivity response to the endocyclic and exocyclic bonds of VCH. The kinetic parameters R_pE, R_pVCH, k_pE, and k_pVCH, which are the apparent rates for the metallocene-catalyzed E/VCH, R_pE, and kpE values, are much more significant than R_pVCH and kpVCH at 120 s, R_pE and R_pVCH 39.63 and 0.78, and the k_pE and kpVCH values are 6461 and 93 L/mol·s, respectively, and minor diffusion barriers are recommended in the early stages. Compared with previously reported PE, R_pE and k_pE values are 34.2 and 7080 L/mol·s. VCH increases the R_pE in the initial stage, as we are expecting; this means that the exocyclic bond of VCH is more active at the initial level, and that the chain transfer reaction of cyclic internal π double is increased with the reaction time. The t_p versus R_p, k_p, and [Zr]/[C*] fraction count may be fitted to a model that invokes deactivation of growing polymer chains. At t_p 120–360 s higher, the incorporation rate of VCH suppresses E insertion, resulting in reduced molecular weight.

Chain Transfer to Solvent and Monomer in Early Transition Metal Catalyzed Olefin Polymerization: Mechanisms and Implications for Catalysis

Even after several decades of intense research, mechanistic studies of olefin polymerization by early transition metal catalysts continue to reveal unexpected elementary reaction steps. In this mini-review, the recent discovery of two unprecedented chain termination processes is summarized: chain transfer to solvent (CTS) and chain transfer to monomer (CTM), leading to benzyl/tolyl and allyl type chain ends, respectively. Although similar transfer reactions are well-known in radical polymerization, only very recently they have been observed also in olefin insertion polymerization catalysis. In the latter context, these processes were first identified in Ti-catalyzed propene and ethene polymerization; more recently, CTS was also reported in Sc-catalyzed styrene polymerization. In the Ti case, these processes represent a unique combination of insertion polymerization, organic radical chemistry and reactivity of a M(IV)/M(III) redox couple. In the Sc case, CTS occurs via a σ-bond metathesis reactivity, and it is associated with a significant boost of catalytic activity and/or with tuning of polystyrene molecular weight and tacticity. The mechanistic studies that led to the understanding of these chain transfer reactions are summarized, highlighting their relevance in olefin polymerization catalysis and beyond.

Kinetic and Thermal Study of Ethylene and Propylene Homo Polymerization Catalyzed by ansa-Zirconocene Activated with Alkylaluminum/Borate: Effects of Alkylaluminum on Polymerization Kinetics and Polymer Structure

The kinetics of ethylene and propylene polymerization catalyzed by homogeneous metallocene were investigated using 2-thiophenecarbonyl chloride followed by quenched-flow methods. The studied metallocene catalysts are: rac-Me2Si(2-Me-4-Ph-Ind)2ZrCl2 (Mt-I), rac-Et(Ind)2ZrCl2 (Mt-II) activated with ([Me2NPh][B(C6F5)4] (Borate-I), [Ph3C][B(C6F5)4] (Borate-II), and were co-catalyzed with different molar ratios of alkylaluminum such as triethylaluminium (TEA) and triisobutylaluminium (TIBA). The change in molecular weight, molecular weight distribution, microstructure and thermal properties of the synthesized polymer are discussed in detail. Interestingly, both Mt-I and Mt-II showed high activity in polyethylene with productivities between 3.17 × 106 g/molMt·h to 5.06 × 106 g/molMt·h, activities were very close to each other with 100% TIBA, but Mt-II/borate-II became more active when TEA was more than 50% in cocatalyst. Similarly, Polypropylene showed the highest activity of 11.07 106 g /molMt·h with Mt-I/Borate-I/TIBA. The effects of alkylaluminum on PE molecular weight were much more complicated; MWD curve changed from mono-modal in Mt-I/borate-I/TIBA to bimodal type when TIBA was replaced by different amounts of TEA. In PE, the active center fractions [C*]/[Zr] of Mt-I/borate were higher than that of Mt-II/borate and average chain propagation rate constant (k p) value slightly decreased with the increase of TEA/TIBA ratio, but the Mt-II/borate systems showed higher k p 1007 k p (L/mol·s). In PP, the Mt-I/borate presented much higher [C*]/[Zr] and k p value than the Mt-II. This work also extend to investigate the mechanistic features of zirconocenes catalyzed olefin polymerizations that addressed the largely unknown issues in zirconocenes in the distribution of the catalyst, between species involved in polymer chain growth and dormant state. In both metallocene systems, chain transfer with alkylaluminum is the dominant way of chain termination. To understand the mechanism of cocatalyst effects on PE Mw and (MWD), the unsaturated chain ends formed via β-H transfer have been investigated by 1H NMR analysis.

Polymethylaluminoxane organic frameworks (sMAOF) – highly active supports for slurry phase ethylene polymerisation

A series of modified solid polymethylaluminoxane (sMAO) catalyst supports have been developed for slurry phase ethylene polymerisation, using aryl di-ol modifier groups.

Rapid kinetic evaluation of homogeneous single-site metallocene catalysts and cyclic diene: how do the catalytic activity, molecular weight, and diene incorporation rate of olefins affect each other?

The kinetics and mechanism of ethylene and cyclic diene 5-ethylidene-2-norbornene (ENB) copolymerization catalyzed by rac-Et(Ind)₂ZrCl₂/[Ph₃C][B(C₆F₅)₄]/triisobutylaluminium (TIBA) were investigated using a quench-labeling procedure using 2-thiophenecarbonyl chloride (TPCC). The E/ENB copolymers were characterized by gel permeation chromatography (GPC), differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and ¹H nuclear magnetic resonance (NMR) spectroscopy and sulfur analysis. To reduce the errors of the ethylene–diene copolymerization for the kinetics study, we selected E/ENB with steric and electronic features that permit us to elucidate the metallocene catalyst behavior against dienes. A quantitative approach of catalyst speciation, stereodynamics, and micro-kinetics assisted the resolution of mechanistic problems, such as the elastomeric synthesis of ethylene propylene diene monomer rubber (EPDM), the catalyst resting state nature, and how much ion-pairing occurs during polymerization. We report here the precise observation of metal–polymer species, explanation of the dynamics of their initiation, propagation, and termination, and ethylene ENB copolymer development. An approach based on acyl chloride was used to selectively quenched transition metal–polymer bonds to evaluate the polymeric catalyst in terms of its reaction rate, R_p, propagation rate content, k_p, and mole fraction of active centers. It is noted that the decline in catalytic activity in the range of 1800 s, and the active center [Zr]/[*C] fraction significantly increased during the initial 1000 s and then tended towards a steady figure of 86%. It is suggested that nearly complete initiation of all olefins catalysts can be obtained after a sufficiently extended reaction. The quick increase in active sites in the first stage can be described by the immediate initiation of active sites positioned on the surfaces of catalyst particles. The initial polymerization rate, R_p, is high and the crystalline properties of the E/ENB copolymer are low due to the greater incorporation of ENB in the polymer backbone, and later the polymerization reaction rates remained stable with a lower mol% of ENB. The melting temperature (T_m) ranges from 108 to 127 °C, whereas the crystalline temperature ranges from 63 to 108 (J g⁻¹). In the E–ENB copolymers, the value of k_pE is much greater than that of k_pENB; at 120 s, the k_pE and k_pENB values are 9115 and 431 L mol⁻¹ s⁻¹, respectively, implying smaller diffusion barriers in the early stages, which are close to the actual propagation rate constant.

The kinetics and mechanism of ethylene and 5-ethylidene-2-norbornene copolymerization catalyzed by rac-Et(Ind)₂ZrCl₂ were investigated using 2-thiophenecarbonyl chloride.

{Cyclopentadienyl/Fluorenyl}-Group 4 ansa-Metallocene Catalysts for Production of Tailor-Made Polyolefins

The development of new metallocene-based polymerization catalysts and innovative processes derived thereof still constitutes a challenge for the manufacturing of polyolefinic materials with tailored properties (e. g. particular microstructure or topology, ultra-high molecular weight, high melting transition, and their combinations) for contemporary commercial applications. This personal account summarizes our continuing endeavors to advance the family of industry-relevant stereoselective propylene polymerization catalysts based on C₁ -symmetric group 4 ansa-metallocenes incorporating multi-substituted fluorenyl-cyclopentadienyl {Cp/Flu} ligands. Within the framework of this project, valuable structural and catalytic data, harvested both for neutral metallocenes and for metallocenium ion-pairs, have been used for rational design of more efficient catalytic systems, reluctant towards side reactions, and for providing new stereoregular value-added polymer materials.

Real-time analysis of methylalumoxane formation

Methylalumoxane (MAO), a perennially useful activator for olefin polymerization precatalysts, is famously intractable to structural elucidation, consisting as it does of a complex mixture of oligomers generated from hydrolysis of pyrophoric trimethylaluminum (TMA). Electrospray ionization mass spectrometry (ESI-MS) is capable of studying those oligomers that become charged during the activation process. We have exploited that ability to probe the synthesis of MAO in real time, starting less than a minute after the mixing of H₂O and TMA and tracking the first half hour of reactivity. We find that the process does not involve an incremental build-up of oligomers; instead, oligomerization to species containing 12–15 aluminum atoms happens within a minute, with slower aggregation to higher molecular weight ions. The principal activated product of the benchtop synthesis is the same as that observed in industrial samples, namely [(MeAlO)₁₆(Me₃Al)₆Me]⁻, and we have computationally located a new sheet structure for this ion 94 kJ mol⁻¹ lower in Gibbs free energy than any previously calculated.

The activator methylaluminoxane is made by hydrolysis of trimethylaluminum. Analysis using ESI-MS reveals rapid formation of small oligomers is followed by slower aggregation to the larger precursors most capable of releasing [Me₂Al]⁺.

The mechanism of the reaction between MAO and TMA: DFT study of the electronic structure and characterization of transition states for [AlOMe]6, [AlOMe]9 and [AlOMe]16 cages

Methylaluminoxane (MAO) and trimethylaluminium (TMA) are relevant compounds in organometallic catalysis. Despite many published studies, aspects of their interaction persist an unsolved puzzle. Hence, in this work, we used quantum mechanic approaches based on density functional theory to study this topic. Our calculations revealed that interaction between MAO and TMA occurs initially by the formation of an intermediary Lewis adduct. In agreement with the latent acidity concept, the activation energy for the tensioned Al-O bond break is small, and changes with the local environment of the MAO cages. Breakage of bond belonging to two square faces requires between 4.20 and 5.80 kcal/mol, whereas square-hexagonal faces demand 0.61-9.43 kcal/mol. The products of this reaction present a terminal, acidic 3-coordinate aluminum atom, that can be capped by another TMA molecules. However, our computations suggest that entropic effects may prevent this reaction from occurring at all these sites in the MAO models studied. Additionally, we also characterize the inter/intramolecular methane elimination mechanism. These reactions are not feasible at room temperature but may occur at high temperatures.

Reactivity Trends of Lewis Acidic Sites in Methylaluminoxane and Some of Its Modifications

The established model cluster (AlOMe)16(AlMe3)6 for methylaluminoxane (MAO) cocatalyst has been studied by density functional theory, aiming to rationalize the different behaviors of unmodified MAO and TMA-depleted MAO/BHT (TMA = trimethylaluminum; BHT = 2,6-di-tert-butyl-4-methylphenol), highlighted in previous experimental studies. The tendency of the three model Lewis acidic sites A-C to release neutral Al fragments (i.e., AlMe2R; R = Me or bht) or transient aluminum cations (i.e., [AlMeR]+) has been investigated both in the absence and in the presence of neutral N-donors. Sites C are most likely responsible for the activation capabilities of TMA-rich MAO, but TMA depletion destabilizes them, possibly inducing structural rearrangements. The remaining sites A and B, albeit of lower Lewis acidity, should be still able to release cationic Al fragments when TMA-depleted modified MAOs are treated with N-donors (e.g. [AlMe(bht)]+ from MAO/BHT). These findings provide tentative interpretations for earlier observations of donor-dependent ionization tendencies of MAO and MAO/BHT and how TMA depleted MAOs can still be potent activators.

Propylene Polymerization Catalyzed by Metallocene /Methylaluminoxane Systems on Rice Husk Ash

Silica generated from agricultural waste is more cost effective and environmentally friendly than silica from traditional commercial processes. In this study, spherical silica particles with a diameter of around 120 nm were fabricated from rice husk ash (RHA), and were used to support two bridged zirconcene complexes ((I) Me₂Si(Ind)₂ZrCl₂ and (II) C₂H₄(Ind)₂ZrCl₂) for catalyzing propylene polymerization to produce polypropylene (PP) in a temperature range of 40–70 °C and in a solution methylaluminoxane (MAO) range of 0.1–0.6 wt%. Due to its small particle size, RHA-supported catalyst exhibited much higher activity than micro-sized commercial silica-supported catalyst. At the optimum polymerization temperature of 55 °C and with increasing MAO concentration, polymer yield increased proportionally with the increase of number average molecular weight. Compared to (I), (II) produced more polymer molecules but with much shorter chain length, ascribed to the differences of Zr loading and bridge structure. With increasing polymerization temperature, polymer molecular weight decreased rapidly and resulted in a significant change of PP assembly morphology (shape and size). At 55 °C, (I) produced uniform PP assemblies which had dumbbell-like structure with a smooth middle section and two fibrillar ends, while (II) produced spherical PP particles. The dumbbell middle part width was essentially identical to the Batchelor microscale proposed in turbulent mixing theory.

Modifying methylalumoxane via alkyl exchange

Methylalumoxane (MAO) ionizes highly selectively in the presence of octamethyltrisiloxane (OMTS) to generate [Me₂Al·OMTS]⁺ [(MeAlO)₁₆(Me₃Al)₆Me]^-. We can take advantage of this transformation to examine the reactivity of a key component of MAO using electrospray ionization mass spectrometry (ESI-MS), and here we describe the reactivity of this pair of ions with other trialkyl aluminum (R₃Al) components. Using continuous injection methods, we found Et₃Al to exchange much faster and extensively at room temperature in fluorobenzene (t_½∼2 s, up to 25 exchanges of Me for Et) than iBu₃Al (t_½∼40 s, up to 11 exchanges) or Oct₃Al (t_½∼200 s, up to 7 exchanges). The exchanges are reversible and the methyl groups on the cation are also observed to exchange with the added R₃Al species. These results point to the reactive components of MAO having a structure that deviates significantly from the cage-like motifs studied to date.

Role(s) of TMA in polymerization

Quenched-flow data for propene polymerization with rac-Me2Si(2-Me-4-Ph-1-indenyl)2ZrCl2/MAO support a picture where removal of MAO qualitatively changes the kinetic profile from a mainly enthalpic to a mainly entropic barrier. DFT studies suggest that a not previously recognized singly-bridged end-on coordination mode of Me6Al2 to catalytically active centers may be kinetically relevant as a resting state. In contrast, the more traditional doubly-bridged complex of Me3Al is proposed to be more relevant to chain transfer to cocatalyst.

Synthesis and spectroscopic characterization of group 4 post-metallocenes bearing (σ-aryl)-2-phenolate-6-pyridyl and -isoquinolinyl auxiliaries

A new series of group 4 bis(benzyl) complexes supported by (σ-aryl)-2-phenolate-6-pyridyl [O,C,N] ligands have been prepared, and all derivatives have been characterized by multinuclear NMR spectroscopy. In the (1)H NMR spectrum of the Ti derivative where [N] = (ortho-F)-substituted isoquinolinyl, one of the two CH2 resonances is observed as a doublet of doublets (collapsing to a normal d upon (19)F-decoupling), whereas the [(1)H,(19)F]-HMQC correlation spectrum reveals a strong crosspeak for this dd resonance only, thus indicating the presence of intramolecular C-HF-C interactions. [(1)H,(19)F]-HMBC experiments have been performed which reveal a significant scalar component for this coupling and confirm that the interactions are genuine. The contrasting NMR spectral patterns for the (ortho-F)-pyridyl Hf analogue, which exhibits two sets of non-identical doublet of doublets for the methylene resonances, have been rationalized. The activities of the isoquinolinyl-based Ti-[O,C,N] catalysts for ethylene polymerization are superior to those of pyridyl-based congeners.

The behaviour of β-triketimine cobalt complexes in the polymerization of isoprene

Cobalt complexes of β-triketimines activated by Et₂AlCl polymerize isoprene to give up to 80%cis-1,4 with 20% 3,4 polymer, at 35 °C.

Zirconium allyl complexes as participants in zirconocene-catalyzed α-olefin polymerizations

In a search for the hitherto elusive catalyst resting state(s) of zirconocene-based olefin polymerization catalysts, a combination of UV/Vis and NMR spectrometric methods reveals that polymer-carrying cationic Zr allyl complexes make up about 90 % of the total catalyst concentration. Other catalyst species that take part in the polymerization process have to be generated from this allyl pool into which they appear to relapse rather frequently.

Formation of octameric methylaluminoxanes by hydrolysis of trimethylaluminum and the mechanisms of catalyst activation in single-site α-olefin polymerization catalysis

Hydrolysis of trimethylaluminum (TMA) leads to the formation of methylaluminoxanes (MAO) of general formula (MeAlO)n (AlMe3)m. The thermodynamically favored pathway of MAO formation is followed up to n=8, showing the major impact of associated TMA on the structural characteristics of the MAOs. The MAOs bind up to five TMA molecules, thereby inducing transition from cages into rings and sheets. Zirconocene catalyst activation studies using model MAO co-catalysts show the decisive role of the associated TMA in forming the catalytically active sites. Catalyst activation can take place either by Lewis-acidic abstraction of an alkyl or halide ligand from the precatalyst or by reaction of the precatalyst with an MAO-derived AlMe2(+) cation. Thermodynamics suggest that activation through AlMe2(+) transfer is the dominant mechanism because sites that are able to release AlMe2(+) are more abundant than Lewis-acidic sites. The model catalyst system is demonstrated to polymerize ethene.