Metallocene Polymerization Catalysts

However, there is also a major difference between the two types of catalysts. The olefin polymerization metallocene catalysts (cf. Section 2.3.1.1) are much more electrophilic, due to the higher positive charge of the metal ion, than the pal-ladium(II) complexes discussed above. For polyketone formation, electrophilicity needs to be balanced so that olefins can still compete with carbon monoxide for coordination to the metal cation. 

EPM [poly(ethylene-co-propylene)] and EPDM [poly(ethylene-co-propylene-co-5-ethylidene-2-norbomene)P can be metallocene catalyst polymerized. Metallocene catalyst technologies include (1) Insite, a constrained geometry group of catalysts used to produce AfiGnity polyolefin plastomers (POP), Elite PE, Nordel EPDM, and Engage polyolefin elastomers (POP) and (2) Exxpol ionic metallocene catalyst compositions used to produce Exact plastomer octene copolymers.2 Insite technology produces EPDM-based Nordel IP with property consistency and predictability (see Sec. 3.2.2). 

Olefin polymerization Metallocene catalyst Tioni, Spitz, Broyer, Monteil, and McKenna (2012) Machado, Lima, Pinto, and McKenna (2011)... 

Abstract. This paper presents results from quantum molecular dynamics Simula tions applied to catalytic reactions, focusing on ethylene polymerization by metallocene catalysts. The entire reaction path could be monitored, showing the full molecular dynamics of the reaction. Detailed information on, e.g., the importance of the so-called agostic interaction could be obtained. Also presented are results of static simulations of the Car-Parrinello type, applied to orthorhombic crystalline polyethylene. These simulations for the first time led to a first principles value for the ultimate Young s modulus of a synthetic polymer with demonstrated basis set convergence, taking into account the full three-dimensional structure of the crystal. 

EinaHy, in 1976, Kaminsky and Sinn in Germany discovered a new family of catalysts for ethylene polymerization. These catalysts (ie, Kaminsky catalysts) contain two components a metallocene complex, usually a zkconocene, and an organoaluminum compound, methylaluminoxane (8,9). These catalysts and thek various later modifications enable the synthesis of ethylene copolymers with a high degree of branching uniformity. Formally classified as MDPE, LLDPE, or VLDPE, the resins thus produced have a number of properties that set them apart from common PE resins in terms of performance... 

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. 

Eluidized-bed reactors are highly versatile and can accommodate many types of polymerization catalysts. Most of the catalysts used for LLDPE production are heterogeneous Ziegler catalysts, in both supported and unsupported forms. The gas-phase process can also accommodate supported metallocene catalysts that produce compositionaHy uniform LLDPE resins (49—51). 

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). 

Metallocene Catalysts. Polymerization of cycloolefins with Kaminsky catalysts (combinations of metallocenes and methylaluminoxane) produces polymers with a completely different stmcture. The reactions proceeds via the double-bond opening in cycloolefins and the formation of C—C bonds between adjacent rings (31,32). If the metallocene complexes contain bridged and substituted cyclopentadienyl rings, such as ethylene(hisindenyl)zirconium dichloride, the polymers are stereoregular and have the i j -diisotactic stmcture. 

Polymerization Reactions. Polymerization addition reactions are commercially the most important class of reactions for the propylene molecule and are covered in detail elsewhere (see Olefin polymers, polypropylene). Many types of gas- or liquid-phase catalysts are used for this purpose. Most recently, metallocene catalysts have been commercially employed. These latter catalysts requite higher levels of propylene purity. 

Catalyst Development. Traditional slurry polypropylene homopolymer processes suffered from formation of excessive amounts of low grade amorphous polymer and catalyst residues. Introduction of catalysts with up to 30-fold higher activity together with better temperature control have almost eliminated these problems (7). Although low reactor volume and available heat-transfer surfaces ultimately limit further productivity increases, these limitations are less restrictive with the introduction of more finely suspended metallocene catalysts and the emergence of industrial gas-phase fluid-bed polymerization processes. 

EPR and EPDM have been made by either solution or emulsion polymerization processes. More recently a new process involving gas-phase polymerization and metallocene catalysts promises to capture large shares of these markets. These new polymers will be especially attractive in automotive apphcations and wine and cable where theh favorable pricing should be welcome. 

A long-standing goal in polyolefins is the synthesis of polymers bearing polar functional groups such as acrylate, esters, or vinyl ethers, etc [24,40]. These copolymers might endow polyolefins with useful properties such as adhesiveness, dyeability, paintability, and print-ibility. Advances have recently been made in polymerizing polar monomers with cationic metallocene catalysts... 

Catalyst, metallocene Also called single site, Me and m. Metallocene catalysts achieve creativity and exceptional control in polymerization and product design permitting penetration of new markets and expand on of present markets. 

The successful polymerization of a, >-dienes via ADMET continually produces a small molecule, typically ethylene, and the removal of this small molecule drives the reaction. When Schrock s [W] and [Mo] alkylidenes (14) are used, care has to be taken in maintaining an inert atmosphere devoid of both moisture and air in order to avoid decomposition of the catalyst. For this reason, Schlenk line techniques such as those used to handle Ziegler-Natta or metallocene catalysts and high purity monomers are important. 

The goal of precise synthesis of supported mononuclear and polynuclear metal complexes can be traced to the early work of Yermakov [1], Ballard [2], and others. Their work stimulated the hvely field referred to as surface organometalhc chemistry [3-6]. The success and importance of precise synthesis of supported molecular catalysts are illustrated by the apphcation of supported metallocene catalysts for industrial alkene polymerization [7j. 

A final example of homogeneous catalysis is the use of metallocene catalyst systems in chain growth polymerization processes. The metallocene, which consists of a metal ion sandtviched between two unsaturated ring systems, is activated by a cocatalyst. The activated catalyst complexes with the monomer thereby reducing the reaction s energy of activation. This increases the rate of the reaction by up to three orders of magnitude. 

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