Catalysts system

Most of the catalyst systems used for HDPE can also be used to make LLDPE. These include Ziegler s original titanium chloride, the later vanadium version, the Phillips chromox system, and the metallocene catalysts described in Section 3.9. Vanadium catalysts yield a substantial fraction of high-molecular weight polymer, while the titanium catalysts yield a molecular weight distribution (PI = 3.5-6) that is narrower than those of vanadium and chromox catalysts. The more recent metallocene systems produce polymers with PI values approaching two. 

The first commercial process for making LLDPE was the Sclair technology developed by Dupont Canada and now implemented by NOVA Chemicals. This process involves high-temperature solution polymerization. Much LLDPE is now made in gas-phase reactors with butene or hexene as the co-monomer. The constrained-geometry catalyst (CGC) is a metallocene catalyst developed by Dow Chemical for the manufacture of linear, very-low density polyethylene resins by solution polymerization with octene as the comonomer. For a given co-monomer content, the solid-state density is lower for octene than for lower a-olefins. 

With the exception of a few solution processes such as one used to make ethylene-propylene copolymers, traditional CCC ( Ziegler-Natta ) catalysts, which were used to make all linear polyethylenes until the advent of the metallocene catalysts, have multiple active center types and therefore yield polymers having a moderately broad MWD and CCD. Techniques used to control the distribution include blending, use of mixed catalysts or cocatalysts, and the use of staged batch reactors or multiple, cascaded continuous reactors. These techniques complicated the already poorly-defined MWD due to the heterogeneity of the catalyst, and as a result, the distribution could not be reliably modeled or described using the standard equations presented in Chapter 3. 

A major breakthrough was the development of a new family of CCC catalysts capable of yielding polyolefins having simply-defined and well-controlled molecular weight distributions. The industrial application of these catalysts only became practical when Kaminsky discovered in 1976 that water-treated trimethylaluminum (methylaluminoxane, MAO) cocatalyst dramatically increased their activities. The new catalysts were called metallocene or single- 

Single-site catalysts have been used to prepare some interesting new polymers. For example, isotactic polystyrene can be made that cools to a brittle, semi-crystalline solid. Copolymers of ethylene and styrene are also possible, and these have glass transition temperatures that decrease progressively below that of polystyrene as the proportion of ethylene in the copolymer is increased. 

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Feedstocks come mainly from catalytic cracking. The catalyst system is sensitive to contaminants such as dienes and acetylenes or polar compounds such as water, oxygenates, basic nitrogen, organic sulfur, and chlorinated compounds, which usually require upstream treatment. 

Technically, acetaldehyde is mainly made by the oxidation of ethylene using a CuCl2/PdCl2 catalyst system.. Although some acetic acid is still prepared by the catalytic oxidation of acetaldehyde, the main process is the catalytic oxidation of paraffins, usually -butane. 

In these (and other) solid superacid catalyst systems, bi- or multi-dentate interactions are thns possible, forming highly reactive intermediates. This amounts to the solid-state equivalent of protosolvation resulting in superelectrophilic activation. 

Recently, a nice bee named Quirks submitted an article from our new, favorite patron researcher Rajender S. Varma. This time the good doctor is tackling our azide problem with another novel use of his clay phase transfer catalyst system. This is just going to be... 

The oxidation of simple internal alkenes is very slow. The clean selectiv oxidation of a terminal double bond in 40, even in the presence of an internt double bond, is possible under normal conditions[89,90]. The oxidation c cyclic alkenes is difficult, but can be carried out under selected condition Addition of strong mineral acids such as HCIO4, H2S04 and HBF4 accelerate the oxidation of cyclohexene and cyclopentene[48,91], A catalyst system 0 PdSO4-H3PM06W6Oii(j [92] or PdCF-CuCF m EtOH is used for the oxidatioi of cyclopentene and cyclohexene[93]. 

In contrast to oxidation in water, it has been found that 1-alkenes are directly oxidized with molecular oxygen in anhydrous, aprotic solvents, when a catalyst system of PdCl2(MeCN)2 and CuCl is used together with HMPA. In the absence of HMPA, no reaction takes place(100]. In the oxidation of 1-decene, the Oj uptake correlates with the amount of 2-decanone formed, and up to 0.5 mol of O2 is consumed for the production of 1 mol of the ketone. This result shows that both O atoms of molecular oxygen are incorporated into the product, and a bimetallic Pd(II) hydroperoxide coupled with a Cu salt is involved in oxidation of this type, and that the well known redox catalysis of PdXi and CuX is not always operalive[10 ]. The oxidation under anhydrous conditions is unique in terms of the regioselective formation of aldehyde 59 from X-allyl-A -methylbenzamide (58), whereas the use of aqueous DME results in the predominant formation of the methyl ketone 60. Similar results are obtained with allylic acetates and allylic carbonates[102]. The complete reversal of the regioselectivity in PdCli-catalyzed oxidation of alkenes is remarkable. 

Using a catalyst system of PdCl2, CuCH, HCl, and O2, the internal alkyne 20 is carbonylated at room temperature and 1 atm to give unsaturated esters[19]. This apparently oxidizing system leads to non-oxidative cu-hydroesterilica-tion. With terminal alkynes, however, oxidative carbonylation is observed. 

Before the development of the Ziegler-Natta catalyst systems (Section 6 21) polymer ization of propene was not a reaction of much value The reason for this has a stereo chemical basis Consider a section of polypropylene... 

Coordination polymerization of isoprene using Ziegler-Natta catalyst systems (Section 6 21) gives a material similar in properties to natural rubber as does polymerization of 1 3 butadiene Poly(1 3 buta diene) is produced in about two thirds the quantity of SBR each year It too finds its principal use in tires... 

Recent patent activity suggests that DuPont is developing a new generation of chelating diphosphite—nickel catalysts for this technology which are significantly more active than the monodentate phosphite based catalyst system used for the last two decades (61—64). 

A yield of about 95% of theoretical is achieved using this process (1.09 units of isopropyl alcohol per unit of acetone produced). Depending on the process technology and catalyst system, such coproducts as methyl isobutyl ketone and diisobutyl ketone can be produced with acetone (30). 

During the reaction, the palladium catalyst is reduced. It is reoxidized by a co-catalyst system such as cupric chloride and oxygen. The products are acryhc acid in a carboxyUc acid-anhydride mixture or acryUc esters in an alcohoHc solvent. Reaction products also include significant amounts of 3-acryloxypropionic acid [24615-84-7] and alkyl 3-alkoxypropionates, which can be converted thermally to the corresponding acrylates (23,98). The overall reaction may be represented by ... 

Both oae-step and two-step oxidation processes are known. A number of catalyst systems are known most use a molybdenum compound as the main component. The acryhc acid is esterified with alcohol to the desired acryhc ester ia a separate process (63—66). 

Other Plastics Uses. The plasticizer range alcohols have a number of other uses in plastics hexanol and 2-ethylhexanol are used as part of the catalyst system in the polymerization of acrylates, ethylene, and propylene (55) the peroxydicarbonate of 2-ethylhexanol is utilized as a polymerization initiator for vinyl chloride various trialkyl phosphites find usage as heat and light stabHizers for plastics organotin derivatives are used as heat stabHizers for PVC octanol improves the compatibHity of calcium carbonate filler in various plastics 2-ethylhexanol is used to make expanded polystyrene beads (56) and acrylate esters serve as pressure sensitive adhesives. 

The direct oxidation of ethylene is used to produce acetaldehyde (qv) ia the Wacker-Hoechst process. The catalyst system is an aqueous solution of palladium chloride and cupric chloride. Under appropriate conditions an olefin can be oxidized to form an unsaturated aldehyde such as the production of acroleia [107-02-8] from propjiene (see Acrolein and derivatives). 

The acetic anhydride process employs a homogeneous rhodium catalyst system for reaction of carbon monoxide with methyl acetate (36). The plant has capacity to coproduce approximately 545,000 t/yr of acetic anhydride, and 150,000 t/yr of acetic acid. One of the many challenges faced in operation of this plant is recovery of the expensive rhodium metal catalyst. Without a high recovery of the catalyst metal, the process would be uneconomical to operate. 

Suitable catalysts are /-butylphenylmethyl peracetate and phenylacetjdperoxide or redox catalyst systems consisting of an organic hydroperoxide and an oxidizable sulfoxy compound. One such redox initiator is cumene—hydroperoxide, sulfur dioxide, and a nucleophilic compound, such as water. Sulfoxy compounds are preferred because they incorporate dyeable end groups in the polymer by a chain-transfer mechanism. Common thermally activated initiators, such as BPO and AIBN, are too slow for use in this process. 

Metal Alibis and Alkoxides. Metal alkyls (eg, aluminum boron, sine alkyls) are fairly active catalysts. Hyperconjugation with the electron-deficient metal atom, however, tends to decrease the electron deficiency. The effect is even stronger in alkoxides which are, therefore, fairly weak Lewis acids. The present discussion does not encompass catalyst systems of the Ziegler-Natta type (such as AIR. -H TiCl, although certain similarities with Friedel-Crafts systems are apparent. 

G-5 Aliphatic Petroleum Resins. Carbocationic polymerization of C-5 feedstreams has been accomptished with various Friedel-Crafts catalyst systems. Table 3 compares the efficiencies of selected Lewis acids ia the polymerization of a typical C-5 stream containing 43 wt % C-5—C-6 diolefias and 47 wt % C-5—C-6 olefins (20). Based on weight percent yield of resia at equimolar coaceatratioas of catalyst (5.62 mmol/100 g), efficieacy follows AICI3 AlBr3 > BF3etherate-H20 > TiCfy > SnCl. The most commonly used catalyst in petroleum resin synthesis is AlCl. ... 

Catalysts used in the polymerization of C-5 diolefins and olefins, and monovinyl aromatic monomers, foUow closely with the systems used in the synthesis of aHphatic resins. Typical catalyst systems are AlCl, AIBr., AlCl —HCl—o-xylene complexes and sludges obtained from the Friedel-Crafts alkylation of benzene. Boron trifluoride and its complexes, as weU as TiCl and SnCl, have been found to result in lower yields and higher oligomer content in C-5 and aromatic modified C-5 polymerizations. 

Catalyst systems used in the commercial synthesis of aromatic petroleum resins are very similar to those systems used in the manufacture of C-5 and C-5—C-9 type resins. The principal catalysts are AlCl and BF and their respective complexes. BF catalysis usually yields resins with improved color over AlCl catalyzed systems. 

Particular drawbacks of using alkylsiHcon and alkyltin haHdes with AlCl for the cationic polymerization of terpenes are low yields and the fact that they require rigorously dried feeds (<50 ppm H2O) to be effective. Increased water content results in lower yields and lower softening points (85). Catalyst systems comprised of AlCl with antimony haHdes in the presence or absence of a lower alkyl, alkenyl, or aralkyl haHde are particularly effective in systems containing up to 300 ppm H2O (89,90). Use of 2—12 wt % of a system composed of 2—3 parts AlCl, 0.7—0.9 parts SbCl, and 0—0.2 parts of an organic... 

Catalysts. Iodine and its compounds ate very active catalysts for many reactions (133). The principal use is in the production of synthetic mbber via Ziegler-Natta catalysts systems. Also, iodine and certain iodides, eg, titanium tetraiodide [7720-83-4], are employed for producing stereospecific polymers, such as polybutadiene mbber (134) about 75% of the iodine consumed in catalysts is assumed to be used for polybutadiene and polyisoprene polymeri2a tion (66) (see RUBBER CHEMICALS). Hydrogen iodide is used as a catalyst in the manufacture of acetic acid from methanol (66). A 99% yield as acetic acid has been reported. In the heat stabiH2ation of nylon suitable for tire cordage, iodine is used in a system involving copper acetate or borate, and potassium iodide (66) (see Tire cords). 

A variation of the Pd/Cu Wacker-Hoechst process, termed OK Technology, has been proposed by Catalytica Associates (40—46). This process avoids the use of chlorides and uses a Pd/Cu catalyst system which incorporates a polyoxoanion and a nitrile ligand. 

Oxidation. Maleic and fumaric acids are oxidized in aqueous solution by ozone [10028-15-6] (qv) (85). Products of the reaction include glyoxyhc acid [298-12-4], oxalic acid [144-62-7], and formic acid [64-18-6], Catalytic oxidation of aqueous maleic acid occurs with hydrogen peroxide [7722-84-1] in the presence of sodium tungstate(VI) [13472-45-2] (86) and sodium molybdate(VI) [7631-95-0] (87). Both catalyst systems avoid formation of tartaric acid [133-37-9] and produce i j -epoxysuccinic acid [16533-72-5] at pH values above 5. The reaction of maleic anhydride and hydrogen peroxide in an inert solvent (methylene chloride [75-09-2]) gives permaleic acid [4565-24-6], HOOC—CH=CH—CO H (88) which is useful in Baeyer-ViUiger reactions. Both maleate and fumarate [142-42-7] are hydroxylated to tartaric acid using an osmium tetroxide [20816-12-0]/io 2LX.e [15454-31 -6] catalyst system (89). 

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