Metallocenes/operation

Molecular Weight Distribution. In industry, the MWD of PE resins is often represented by the value of the melt flow ratio (MER) as defined in Table 2. The MER value of PE is primarilly a function of catalyst type. Phillips catalysts produce PE resins with a broad MWD and their MER usually exceeds 100 Ziegler catalysts provide resins with a MWD of a medium width (MFR = 25-50) and metallocene catalysts produce PE resins with a narrow MWD (MFR = 15-25). IfPE resins with especially broad molecular weight distributions are needed, they can be produced either by using special mixed catalysts or in a series of coimected polymerization reactors operating under different reaction conditions. 

In the early 1990s, solution processes acquired new importance because of their shorter residence times and abiUty to accommodate metallocene catalysts. Many heterogeneous multicenter Ziegler catalysts produce superior LLDPE resins with a better branching uniformity if the catalyst residence time in a reactor is short. Solution processes usually operate at residence times of around 5—10 min or less and are ideal for this catalyst behavior. Solution processes, both in heavy solvents and in the polymer melt, are inherently suitable to accommodate soluble metallocene catalysts (52). For this reason, these processes were the first to employ metallocene catalysts for LLDPE and VLDPE manufacture. 

The second type of solution polymerization concept uses mixtures of supercritical ethylene and molten PE as the medium for ethylene polymerization. Some reactors previously used for free-radical ethylene polymerization in supercritical ethylene at high pressure (see Olefin POLYMERS,LOW DENSITY polyethylene) were converted for the catalytic synthesis of LLDPE. Both stirred and tubular autoclaves operating at 30—200 MPa (4,500—30,000 psig) and 170—350°C can also be used for this purpose. Residence times in these reactors are short, from 1 to 5 minutes. Three types of catalysts are used in these processes. The first type includes pseudo-homogeneous Ziegler catalysts. In this case, all catalyst components are introduced into a reactor as hquids or solutions but form soHd catalysts when combined in the reactor. Examples of such catalysts include titanium tetrachloride as well as its mixtures with vanadium oxytrichloride and a trialkyl aluminum compound (53,54). The second type of catalysts are soHd Ziegler catalysts (55). Both of these catalysts produce compositionaHy nonuniform LLDPE resins. Exxon Chemical Company uses a third type of catalysts, metallocene catalysts, in a similar solution process to produce uniformly branched ethylene copolymers with 1-butene and 1-hexene called Exact resins (56). 

Borstar A catalytic process for polymerizing ethylene. Use of two reactors, a loop reactor and a gas-phase reactor, allows better control of molecular weight distribution. The loop reactor operates under super-critical conditions to avoid bubble formation. Either Ziegler-Natta or metallocene catalysts can be used. The first commercial unit was installed in Porvoo, Finland, in 1995. 

The process operates in the liquid phase by dissolving the ethylene in an inert solvent such as cyclohexane or isopentane. The metallocene catalyst is also injected to the mix. The solvent has several important functions. It keeps in solution the alpha olefins produced as well as the ethylene and catalyst. It also enhances the catalyst activity and selectivity. 

The anion dissociates, and the coordinatively unsaturated metal center then picks up a monomer molecule for subsequent enchainment. This dissociative model has been favored in the past [16, 21-23, 27-28] since it allows a convenient explanation of the observed polymer stereochemistry by considering only the roles of the ligand and the alkyl chain in the cationic metallocene complex. However, anion dissociation opposes the electrostatic attraction between cation and anion and is therefore energetically expensive. So does it operate at all ... 

The mechanism that is commonly considered to operate in the polymerisation of ethylene and a-olefins in the presence of group 4 metallocene-based catalysts is that devised by Cossee [268, 276, 277] for propylene polymerisation with heterogeneous Ziegler-Natta catalysts, though modifications invoking effects such as a-agostic hydrogen interactions with the metal centre have been proposed [343,344]. 

The described chain migratory insertion mechanism, which operates in olefin polymerisation with metallocene-based single-site catalysts, follows that proposed by Cossee [268,277,278] for olefin polymerisation with heterogeneous catalysts there is, however, no back skip of the polymer chain to the previously occupied position prior to the coordination of the next monomer molecule, but rotation of the chain around the axis of the Mt-CH2 bond takes place (Figure 3.19) [358],... 

As regards the insertion mechanism in a-olefin polymerisation with metallocene-based catalysts, one should recall that a chain migratory mechanism is operating, but occasional skipped insertion or a constant skipped insertion mechanism may also be operating (Figure 3.17), depending on the kind of catalyst. 

The discussed mechanism is similar to that operating in the 1,3-enchainment of propylene using metallocene-based catalysts [scheme (67) in chapter 3] [34-39]. 

Because of their acceptable thermal stability ansa-metallocenes are suitable catalysts for high pressure polymerization at temperatures fairly above 100°C. In this investigation a modified silyl-bridged bis(tetrahydroindenyl)zirconocene in toluene as the solvent was used. The cocatalyst was methylaluminoxane (MAO) which was available in a 10 wt% solution also in toluene. The polymerization experiments were performed in a continuously operated laboratory unit equipped with a stirred autoclave (Figure 1). It is described in detail in [6],... 

Borstar A catalytic process for polymerizing ethylene or propylene, subdivided into Borstar PE and Borstar PP. Use of two reactors — a loop reactor and a gas-phase reactor — allows better control of molecular weight distribution. The loop reactor operates under supercritical conditions to avoid bubble formation. Either Ziegler-Natta or metallocene catalysts can be used. The latest version, Borstar PE 2G, uses a single, multizone gas-phase reactor to make polymers that have bimodal molecular weight distributions. Developed by Borealis A/S. The first commercial unit, for polyethylene, was installed in Porvoo, Finland, in 1995. The first polypropylene plant was operated by Borealis in Schwechat, Austria, in 2000. In 2005, Borstar s total capacity for PE and PP was 1.3 million tons. 

More recent studies have shown that a number of other mechanisms are operative in the hydrosilation process for different metals. Mechanistic proposals for early metals, lanthanides and actinides have been elaborated on. These involve a Chalk-Harrod like initial migratory insertion into a metal-hydride bond, followed by a a-bond metathesis step (Scheme 4). An alternative mechanism, however, was proposed for Group 4 metallocene catalysis, which involves a coordinated olefin, which undergoes a-bond metathesis with the hydrosilane. ... 

This reaction can operate starting from a lot of fulvenes. Some allyl-bridged metallocenes can be synthesized by an unusual intramolecular HNMe2 elimination and a fulvene coupling (equation 5). ... 

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