MAO- and Borate-Free Activating Supports for Group 4 Metallocene and Post-Metallocene Catalysts of α-Olefin Polymerization and Oligomerization

Modern industry of advanced polyolefins extensively uses Group 4 metallocene and post-metallocene catalysts. High-throughput polyolefin technologies demand the use of heterogeneous catalysts with a given particle size and morphology, high thermal stability, and controlled productivity. Conventional Group 4 metal single-site heterogeneous catalysts require the use of high-cost methylalumoxane (MAO) or perfluoroaryl borate activators. However, a number of inorganic phases, containing highly acidic Lewis and Brønsted sites, are able to activate Group 4 metal pre-catalysts using low-cost and affordable alkylaluminums. In the present review, we gathered comprehensive information on MAO- and borate-free activating supports of different types and discussed the surface nature and chemistry of these phases, examples of their use in the polymerization of ethylene and α-olefins, and prospects of the further development for applications in the polyolefin industry.

Meso- and Rac-[bis(3-phenyl-6-tert-butylinden-1-yl)dimethylsilyl]zirconium Dichloride: Precatalysts for the Production of Differentiated Polyethylene Products with Enhanced Properties

Ansa-zirconocene complexes are widely employed as precatalysts for olefin polymerization. Their synthesis generally leads to mixtures of their rac and meso isomers, whose separation is often problematic. In this contribution, we report on the synthesis of a novel silyl-bridged bis(indenyl)-based metallocene, and on the separation of its rac and meso isomers by simple recrystallization from toluene. The two complexes, activated by methylaluminoxane (MAO), have been used as precatalysts in ethylene/1-hexene copolymerization. Regardless of the reaction conditions, the meso complex outperformed its rac congener. A similar trend was observed by performing the process in the presence of the silica-supported versions of the complexes. This is remarkable, since meso metallocenes generally display lower activities than their rac analogues. Furthermore, the meso isomer generates polymer products that are more in line with the targets for the preparation of a bimodal PE grade made of a lower-MW high-density (HDPE) fraction and a higher-MW linear low-density (LLDPE) fraction.

Avoiding leaching of silica supported metallocenes in slurry phase ethylene homopolymerization

Leaching of (n-BuCp)₂ZrCl₂/MAO catalyst from silica supports has been studied in slurry phase ethylene homopolymerisation by changing i) the polymerization protocol, ii) aluminum alkyl scavengers and iii) by adding butylated hydroxytoluene (BHT-H) along with aluminum alkyl scavengers.

Silica/MAO/(n-BuCp)2ZrCl2 catalyst: effect of support dehydroxylation temperature on the grafting of MAO and ethylene polymerization

This study reports the role of silica dehydroxylation temperature on the performance of Silica/MAO/(n-BuCp)₂ZrCl₂ catalysts in ethylene homopolymerization.

The design of a bipodal bis(pentafluorophenoxy)aluminate supported on silica as an activator for ethylene polymerization using surface organometallic chemistry

A well-defined solid activator for supported metallocene polymerization catalysts.