NOVEL Ti-Aryl COMPLEXES AS INTERNAL OR EXTERNAL MODIFIERS,
IMPROVING PERFORMANCE OF MgCl2 SUPPORTED POLYPROPYLENE CATALYSTS
Gregory G. Arzoumanidis Oakwood Consulting, Inc. Wheaton, Illinois 60!" arzoumandis#gmail.com oakwoodconsulting.com
Abstrat
$he recently announced multi%site &eha'ior o( some )( organometallic com*le+es in ole(in *olymerizations ,- may &e attri&uted in *art to ole(in insertion into the )(%aryl &ond. We ha'e now a**lied (or the (irst time a num&er o( no'el hindered aromatic com*le+es, (eaturing a $i%aryl &ond and one or more heteroatoms, to demonstrate su&stantial im*ro'ements in catalytic *er(ormance o( .gCl2 su**orted /oly*ro*ylene ,//- catalysts. Com*le+es with other metals, such as 0r, showing identical structures, ha'e also &een *re*ared. $hese com*le+es may &e used either as internal or e+ternal modi(iers o( .gCl2 su**orted // catalysts. As internal modi(iers, they may not re*lace entirely the *hthalates or other well known internal modi(iers. Instead, &y an o*timum *artial re*lacement o( the e+isting modi(iers, they may im*art mainly acti'ity enhancements u* to !01. As e+ternal modi(iers that could &e deli'ered mi+ed with the aluminum alkyl, they may re*lace "0%001 o( the silane commonly used. 2esides the acti'ity enhancement, they are e+*ected to im*art su&stantial im*ro'ements to // *roduct *ro*erties, due to their multi%site &eha'ior. $o take ad'antage o( this technology in a // *rocess, there is no need (or changes in the use and o*eration o( an e+isting .gCl2 su**orted catalyst, e+ce*t (or the addition o( the com*le+es as e+ternal modi(iers. $he com*le+es were *re*ared in a one%*ot, single ste* reaction in toluene o( $iCl3 or 0rCl3 with com*ounds o( the general (ormula Ar+%4%5, where Ar6Aryl attached to 4, +6%3, 46 a *olycyclic or monocyclic heteroaromatic ligand, containing one or more heteroatoms, 56heteroatom a'aila&le (or coordination7&ond (ormation with the metal. $he reaction in'ol'es an orthometallation and (ormation o( a 8% or 6% mem&er metallocyclic ring. $hese com*le+es (urther undergo chemical trans(ormation and metal reduction with aluminum alkyls, such as triethylaluminum ,$5A-. $he resulting *roducts may acce*t a great 'ariety o( a*rotic electron donors. Although we *re*ared only a (ew orthometalated com*le+es, we ha'e identi(ied dozens o( ligands that ha'e the *otential to (orm such com*ounds. I( one counts one or more su&stituents on these ligands, it a**ears that this new technology o((ers endless *ossi&ilities. $he com*le+es are e+*ected to &e utilized as inde*endent catalysts as well, in se'eral other al*ha%ole(in *olymerizations and co*olymerizations such as ethylene, &utene, etc, and *articularly in high tem*erature solution *rocesses. $heir great ad'antage is their acti'ation with aluminum alkyls such as $5A, not .AO or other non%coordinating anions.
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A (lurry o( research acti'ity took *lace in the *ast se'eral years &y // *roducers in de'elo*ing new internal modi(iers (or commercial .gCl2 su**orted catalysts, &eyond the 9classical: *hthalate, succinate, and other esters, and diethers. $he incenti'e (or this acti'ity has &een im*ro'ements in *rocess and *roduct, sa(ety issues, and ac;uiring a *ro*rietary *osition. 5+am*les o( new commercial internal modi(iers are car&onates ,2-, sul(onyl com*ounds ,<-, a *air o( organosilicon com*ounds ,3-, ketone% ether deri'ati'es ,8,6-, ali*hatic cyclic esters ,",!-, ,!%na*hthyl%diaryloates ,=-, and in%situ (ormation o( di%octyl%*hthalate, using an emulsion *rocess to control *article mor*hology ,0-. As *art o( a similar e((ort, we screened se'eral *otential candidates as modi(iers o( a widely used commercial // catalyst, originally de'elo*ed &y us in the =!0s ,-. In order to e+*edite the screening *rocess, we tested the *otential modi(iers as e+ternal modi(iers (irst, using a la&oratory &atch gas *hase unit ,-, and monitored *ossi&le changes in the o'erall catalyst system *er(ormance. $he (irst Ar+%4%5 ty*e material tested ga'e us an a'erage o( <81 increase in // yield, im*ro'ed e+tracta&les and *owder &ulk density. >ollowing u* on this de'elo*ment, and a(ter a series o( e+*eriments discussed &elow, we gradually recognized that, whereas the known internal modi(iers coordinate with the .gCl2 ,2-, the Ar+-L-E interact primarily with the TiCl4 on the catalyst. $his is a key *oint in understanding all the de'elo*ments and *ro*osals we outline in this *a*er, and may re*resent a new conce*t in .gCl2 su**orted // catalysts. $he Ar+%4%5 materials are unrelated to e+isting internal modi(iers o( .gCl2 su**orted // catalysts. In (act, they may not e'en act as modi(iers, &ut com&ined with $iCl3, constitute inde*endent catalytic s*ecies. We &elie'e they re*resent a new class o( $i ,and other transition metals- organometallic com*le+es, (eaturing metal%aryl &onds, disco'ered &y mere serendi*ity. $hey are e+*ected to ha'e interesting and widely ranging a**lications in *olyole(in catalysis. R%s$lts a!# Dis$ssi"! A .gCl2 su**orted // catalyst was *re*ared using an Ar+%4%5 com*ound ,I-, with +62, and a ligand ,4- with a single heteroatom, as the internal modi(ier. $his was the same material which ga'e us earlier the <81 acti'ity increase as an e+teral modi(ier. $he catalyst *re*aration *rocedure has &een descri&ed elsewhere ,-. $he *olymerization test results (rom this catalyst were une+*ectedly in(erior to the control catalyst, *re*ared similarly with di%n% &utyl *hthalate ,?@2/- as the internal modi(ier. We then *roceeded to *re*are catalysts with mi+tures o( ?@2/7,I- at molar ratios o( =070, !878, "8728, and 80780. $he &est *olymerization test results were o&tained (rom the (irst two catalysts, with an acti'ity im*ro'ement o( u* to 681 o'er the control, and signi(icant im*ro'ements in e+tracta&les and *owder &ulk density. We also determined that i( we reduce the amount o( silane in the *olymerization test &y a&out "01, we get an additional acti'ity &oost u* to 201, retaining the e+tracta&les similar to the control. $he last two catalysts at "8728 and 80780 ga'e results similar to the control, in terms o( acti'ity and stereos*eci(icity, &ut there were *ro&lems with lower *owder &ulk density. We then a**lied cross%*olarization with magic angle s*inning ,C/.AA- solid state < C @.B techni;ue to two o( the (our catalyst sam*les, =070 and 80780. $he sam*les were *acked into .AA rotors in dry &o+ under nitrogen. $he s*ectra o( the =070 had only *eaks that could &e assigned to 'arious car&ons o( ?@2/. All maCor @.B *eaks (or ,I- were com*letely o&scured &y the more intense *eaks o( ?@2/. $he 80780 catalyst s*ectrum was similar to the a&o'e, e+ce*t (or an additional small *eak at !< **m, &arely distinguisha&le at the &ase o( the more intense *eak due to car&onyl car&ons o( ?@2/. $he *eak at !< **m could not &e assigned to any car&on o( *ure ,I-. $o clearly identi(y the origin o( this unusually shi(ted < C @.B *eak, we attem*ted to *re*are a *ure D$iCl3 & ,I-E com*le+. We reacted ,I- with $iCl3 in toluene at ele'ated tem*eratures at a molar ratio o( 27. A semi crystalline *roduct was isolated, which crystallized a(ter se'eral washings and dried under 'acuum. 5lemental analysis indicated a D2,I- & <$iCl3E stoichiometry. In the solid state < C @.B o( the com*le+, the !< **m *eak is clearly e'ident, along with all the other *eaks that could &e assigned to ,I-. $he !< **m *eack was now assigned to an aromatic car&on atom directly &onded to $i. $he (ormation o( the $i%Aryl &ond was also *redicted &y com*utational calculations. On the &asis o( analytical, solid state < C @.B, IB ,discussed &elow- and modeling data, we assign the (ollowing structure to the com*le+F Com*le+ ,II- $he )Cl *roduced &y the metallation o( the *henyl grou* is &eing retained in the structure. $he Cl (rom each o( the two )Cl molecules is coordinating with the middle $i, and each ) is &ridging with another Cl &elonging to an end $i. $hus we ha'e the creation o( an D)Cl2E moiety, which has &een demonstrated in se'eral other crystal structures ,<-. $he >$IB s*ectrum o( )Cl on ice *articles at 80 o
G shows a strong D)Cl2E &and at "08 cm % and a weak &and at 28 cm % attri&uted to Cl ... )Cl , a strong &and at 23=8 cm % assigned to )Cl, and a shoulder at 2"80 cm % attri&uted to )Cl solid ,3-. In the IB s*ectrum o( com*le+ ,II- there are two weak &ands at 8=6 cm % and 86! cm %
which we assign to the D)Cl2E moiety. $hese &ands are shi(ted lower &ecause o( the coordination o( the Cl with $i. Also, they are two instead o( one &ecause the three atoms Cl)Cl are *ro&a&ly at an angle and not in a straight lineH 60 o to!0 o angles ha'e &een o&ser'ed ,<-. $here are also corres*onding a&sor*tions at 2<672<<" cm % and 2"2<726!0 cm % . >urthermore, (our 'ery strong a&sor*tions at 3!, 30, <=!, <"8 cm % are assigned to I $i%Cl. 2y com*arison, $iCl3 & ?@2/ com*le+ which has an octahedral con(iguration around $i, synthesized &y us, showed ma+ima at 306, 300, <!<, and <"3 cm % ,8-. A strong &and o( ,I- at 6!8 cm% characteristic o( the (i'e consecuti'e ) atoms o( the *henyl grou* is not *resent in ,II-. Instead, a new strong &and a**ears at "22 cm %
assigned to a (our consecuti'e ) atoms in an aromatic ring, a su**orting e'idence (or the metallation o( the *henyl grou*. Other &ands attri&uted to the heteroatom%car&on &ond, and to the aromatic rings are also *resent. In a similar (ashion we reacted 0rCl3 with ,I- to o&tain a com*le+, which &y < C @.B, IB, and elemental analysis has similar structure to ,II-. Com*le+ ,II- was reacted with Al5t<, and a new *roduct ,III- was isolated. $he )Cl reacts with Al5t< to yield a chlorinated aluminum alkyl Al5tzCl<%z with release o( ethane. A**arently, the organometallic *ortion o( ,II- se*arates out, com*le+ing with the Al ethyl chloride s*ecies also (ormed &y the $i,IJ- to $i,III- reduction. $he num&er o( Cl atoms and ethyl grou*s on Al may 'ary, de*ending on reaction conditions. In one case the 'alue o( z was calculated to &e 0.<.
Com*le+ ,III- $he < C solid state @.B s*ectrum o( ,III- shows a large *eak at ca. 8 **m (rom ethyl grou* car&ons, indicating alkylation on $i and an ethyl aluminum moiety &eing incor*orated in the structure. $he *eak assigned to *henyl car&on &onded to $i is shi(ted (urther to =6 **m. $hese and other analytical data were used to su**ort the *ro*osed structure ,III-. /roduct ,III-, under *olymerizaton conditions is e+*ected to yield *roduct ,IJ-, &y insertion o( the ole(in to the $i%*henyl &ond. ,IJ- ?e*ending on the insertion mode ,,2% or 2,% insertion-, eight stereoisomers, 0 in the case o( ethylene co*olymerization, are e+*ected to &e (ormed ,-. 5ach stereoisomer is e+*ected to ha'e a di((erent im*act on the *olymer *roduced. Com*le+ ,IJ- &elongs to the class o( multi%site catalysts. Catalyst ,IJ- will most likely &e use(ul in ethylene and other ole(in co%*olymerizations. $he im*ortant ad'antage o( ,III- o'er other multi%site catalysts, is the (act that it is acti'ated with Al alkyls rather than .AO or other non% coordinating anions, such as *er(luoro&orates. .i+tures o( ?@2/ with se'en di((erent Ar+% 4%5 com*ounds ha'e &een used at the o*timum !878 molar ratio to *re*are .gCl2 su**orted // catalysts. $hese Ar+%4%5 com*ounds 'aried &y the num&er + ,(rom to 3-, &y the element o( heteroatom ,5- *resent, and &y di((erent ligand structures, (used aromatics or otherwise, that may contain additional heteroatoms, the same or di((erent (rom ,5-. In all catalyst *re*arations, we ha'e assumed that the $i com*le+es are &eing (ormed in situ. $he control was a similarly *re*ared catalyst with ?@2/ as the only internal modi(ier. In all cases the o'erall yield ad'antage (or the catalysts *re*ared with mi+ed modi(iers was &etween 201 and 681, and de*ended u*on the ligand structure and the ty*e o( test ,slurry, gas *hase-.
In most cases, reduction o( the silane e+ternal modi(ier used in the *olymerization test &y "01 increases the yield (urther &y &etween 0%201, without a((ecting the e+tracta&les. It is noteworthy that yield and other ad'antages were o&tained (rom each one o( the se'en ligands in'estigated. )owe'er, the data were too limited to discern accurate structure and *er(ormance relationshi*s. We ha'e identi(ied o'er 80 ligand structures that could *otentially yield *roducts similar to ,II-. C"!l$si"!s . @o'el orthometallated heteroaryl com*le+es o( $i, 0r, and other transition metals (or the stereos*eci(ic *olymerization o( *ro*ylene and other al*ha%ole(ins ha'e &een de'elo*ed. $hese catalysts may &e acti'ated with aluminum alkyls such as $5A and $I2A. 2. $he com*le+es may &e synthesized in a one *ot7single ste* reaction, with o(( the shel(, readily a'aila&le materials. <. $he com*le+es enhance the *er(ormance o( e+isting .gCl2 su**orted // catalysts, and are e+*ected to im*ro'e *olymer *roduct *ro*erties through their multi%site catalytic &eha'ior. 3. $hey may &e used in ethylene and other al*ha%ole(in *olymarizations, either su**orted on silica, silica7alumina etc, or unsu**orted in a high tem*erature solution *rocess. R%'%r%!%s . ?. )ustad et al, K.A. /atent !,<62,62 ,20<-. 2. L. @. Coalter et al, K.A. /atent A**lication 2070<082=, and K.A. /atent !,26<,820 ,202- <. L. Mi et al, K.A. /atent !,303,"!= ,20<-, and K.A. /atent !,3"0,=3 ,20<-. 3. .. )osaka, K.A. /atent !,326,8<" ,20<-. 8. .. Chang, K.A. /atent !,00<,88! ,20-. 6. M. >uCiwara, K.A. /atent !.2!!,3!! ,202-. ". A. 5arnst, K.A. /atent A**lication 20070!00!< ,200-. !. G. .atsunaga et al, K.A. /atent ",!!!,3<! ,20-. =. .. Chang, !,00<,88! ,20-. 0. $. 4einonen et al, K.A. /atent !,26,=8" ,202-. . G.G. Arzoumanidis et al, K.A. /atent 3,=!!,686 ,==-. 2. M.J. Gissin 9Isos*eci(ic /olymerization o( Ole(ins with )eterogeneous 0iegler%@atta Catalysts: A*ringer Jerlag, *. 23!. <. 2.). Ward et al, Chem. .ater., ==!, 0 ,3-, **. 02%0!. Also in NN/h3As O Cl %& )ClNN. 3. L./. ?a'lin et al, @ature, 3", 26= ,2002- 8. G.G. Arzoumanidis et al, 9Catalytic Ole(in /olymerization: /roceedings o( International Aym*osium, $okyo, =!=, Gadansha, 4td.
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