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ABSTRACT: The solution copolymerization of ethylene (1) with octene-1 (2) in Isopar E
using constrained geometry catalyst system, [C5Me4(SiMe2NtBu)]TiMe2 (CGC-Ti)/
tris(pentafluorophenyl)boron (TPFPB)/modified methylaluminoxane (MMAO), has
been carried out in a high-temperature, high-pressure continuous stirred-tank reactor
(CSTR) at 140C, 500 psig and with a mean residence time of 4 min. A series of
copolymer samples with octene-1 content up to 0.337 mole fraction were synthesized
and characterized. The estimated reactivity ratios were r1 5 7.90 and r2 5 0.099. The
CGC-Ti showed a higher ability to incorporate high a-olefins than other metallocene
catalysts investigated in the literature due to its open structure. The presence of
octene-1 lowered the catalyst activity, particularly at octene-1 levels higher than 0.45
mole fraction. Octene-1 was also found to reduce the molecular weight of polymer and
broaden the molecular weight distributions. The triad distributions were measured by
13
C-NMR. A minor penultimate effect was observed. The penultimate octene-1 unit
appeared to slow down monomer insertion rates. A comparison of the propagation rate
of octene-1 with the incorporation rate of macromonomer in the homopolymerization of
ethylene suggests that the addition of macromonomer is effectively instantaneous after
it is generated with diffusion to or from the active center reaction volume playing a
minor role. 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2949 2957, 1999
Keywords: metallocene polymerization; linear low density polyethylene; ethylene/
octene-1 copolymerization; constrained geometry catalyst; continuous solution polymerization; branching; reactivity ratio
INTRODUCTION
Linear low-density polyethylene (LLDPE) is an
important family of ethylene polymers because to
its superior processing properties. Copolymerization of ethylene with small amounts of a-olefins,
i.e. butene-1, hexene-1 and octene-1, produces
LLDPE with short chain branching which lowers
both crystallinity and density. In contrast to conventional ZieglerNatta catalysts, the metallocene catalyst technology provides copolymers
with narrower composition distributions, nar-
2950
WANG ET AL.
of good mechanical properties and processibilities, the best of both worlds.8 11 The CGC active
center is bonded to a monocyclopentadienyl ring
and bridged with a heteroatom unit, forming a
constrained cyclic structure. This geometry allows
the transition metal center to readily incorporate
high a-olefins and macromonomers. In our recent
report on the kinetics of ethylene homopolymerization,11 the ethylene macromonomers were found to
be formed mainly via chain transfer to ethylene.
Branched polyethylenes were produced through the
in situ copolymerization of the macromonomer with
ethylene.
Following up the investigation of the continuous solution homopolymerization of ethylene using CGC, this paper reports the copolymerization
of ethylene with octene-1 using our high-temperature high-pressure continuous stirred-tank reactor (CSTR) system. The copolymerization kinetics
will be discussed and compared with the ethylene
homopolymerization data to further elucidate the
pathway of LCB formation.
EXPERIMENTAL
Materials
All manipulations with organometallic compounds
were conducted using a drybox technique. Catalyst,
[C5Me4(SiMe2NtBu)]TiMe2 (Me: methyl; tBu: isobutyl; C5: cyclopentadiene) (CGC-Ti), and co-catalyst,
tris(pentafluorophenyl)boron (TPFPB), were donated by Dow Chemical as 10 and 3 wt % solution in
Isopar E, respectively. Modified methylaluminoxane (MMAO-3A) was provided by Akzo-Nobel Corporation as 7.2 wt % aluminum in heptane. The
CGC-Ti and co-catalysts were used without further
purification. Polymerization-grade ethylene with
560 ppm (in mole) of hydrogen was from Matheson
Gas and further purified by passing through columns with CuO, Ascarite, and molecular sieves.
Octene-1 from Aldrich was distilled over CaH2. Isopar E (Caledon Laboratories Ltd.) as solvent was
dried over a mixture of 5A and 13X molecular sieves
from Fisher Scientific and silica gel from Caledon
Laboratories Ltd., and de-oxygenated by sparging
with ultra-high purity nitrogen (99.999%) from
Matheson Gas.
Polymerization
The continuous solution polymerization reactor
system used for the kinetic studies of ethylene/
Figure 1.
this work.
2951
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WANG ET AL.
AOEE
AOE 1 E O
(1)
k 12
AOE 1 O O
AOOE
(2)
k 21
AOO 1 E O
AOEO
(3)
2953
Table I. Results of Continuous Solution Copolymerizations of Ethylene (1) and Octene-1 (2) at 140C
Run
(#)
f 20 a
(in mole)
[M 1 ] 0 b
(M)
[M 2 ] 0
(M)
[M 1 ]
(M)
[M 2 ]
(M)
f2
(in mole)
F 2c
(in mole)
MW
(310 24 )
MWD
Activity
(kg Polymer/g
Catalyst)
011
1
2
3
4
5
6
7
A1
A2
0
0.05
0.10
0.20
0.30
0.45
0.60
0.80
1.43
1.36
1.28
1.14
0.998
0.784
0.570
0.285
0
0.071
0.143
0.285
0.428
0.642
0.842
1.14
0.153
0.180
0.181
0.215
0.268
0.200
0.264
0.253
0.274
0.442
0
0.037
0.091
0.194
0.324
0.479
0.736
1.12
0.284
0.659
0
0.170
0.335
0.476
0.547
0.705
0.736
0.816
0.509
0.599
0
0.028
0.045
0.089
0.125
0.218
0.258
0.337
0.124
0.167
10.4
4.44
3.92
2.59
1.96
1.16
1.04
0.791
2.04
1.95
2.03
2.12
2.20
2.21
2.16
2.24
7.27
7.49
7.48
7.36
6.55
7.04
4.19
0.554
Activityd
(3 1024 kg
Polymer/[M]
z mol Ti)
1.56
1.13
0.901
0.589
0.362
0.339
0.137
0.013
k 22
AOO 1 O O
AOOO
(4)
R p1 5
@M 1# 0 2 @M 1#
5 ~k 11@A 1# 1 k 21@A 2#!@M 1#
t
(5)
R p2 5
@M 2# 0 2 @M 2#
5 ~k 22@A 2# 1 k 12@A 1#!@M 2#
t
(6)
(7)
@P 2#
@P 1# 1 @P 2#
5
Figure 3. Monomer conversions (h: ethylene, : octene-1, and F: total) versus the inlet octene-1 molar
fraction ( f20) during the copolymerization of ethylene
and octene-1 at 140C with the constrained geometry
catalyst.
r 2 f 22 1 f 2~1 2 f 2!
r f 1 2f 2~1 2 f 2! 1 r 1~1 2 f 2! 2
2
2 2
(8)
where [P1] and [P2] are the concentrations of monomeric units chemically bound to the copolymer
chains ([Pi] 5 [Mi]0 2 [Mi]), F2 is the molar fraction of octene-1 in copolymer and f2 (5[M2]/([M1]
1 [M2])) is the outlet molar fraction of octene-1.
The reactivity ratios are defined as r1 5 k11/k12
and r2 5 k22/k21.
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WANG ET AL.
Temperature (C)
Comonomer
r1
r2
r1r2
[C5Me4(SiMe2NtBu)]TiMe2/TPFPB/MMAO
meso-Me2Si(2-Me-1-Ind)2ZrCl2/MAO5
rac-Me2Si(2-Me-1-Ind)2ZrCl2/MAO5
rac-Me2Si(Ind)2ZrCl2/MAO7
rac-Me2Si(2-MeInd)2ZrCl2/MAO7
rac-Me2(Si(Benz[e]Ind)2ZrCl2/MAO7
rac-Me2Si(2-MeBenz[e]Ind)2ZrCl2/MAO7
Cp2ZrCl2/MAO3
Et(IndH4)2ZrCl2/MAO3
i-Pr(Cp)(Flu)ZrCl2/MAO3
140
60
60
40
40
40
40
40
40
40
1-Octene
1-Octene
1-Octene
1-Octene
1-Octene
1-Octene
1-Octene
1-Hexene
1-Hexene
1-Hexene
7.90
18.9
19.5
10.7
10.1
21.9
12.9
5.6
0.099
0.014
0.013
0.076
0.118
;0
0.027
0.051
0.78
0.008
0.14
0.27
0.25
0.81
1.20
0.35
0.29
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Table III. The Triad Distributions for Ethylene/Octene-1 Copolymers Synthesized in Continuous Solution
Copolymerizations at 140C
Run (#)
f1
(in molar)
P(EOE)
(%)
P(EOO 1 OOE)
(%)
P(OOO)
(%)
P(OEO)
(%)
P(OEE 1 EEO)
(%)
P(EEE)
(%)
1
2
3
4
5
6
7
A1
A2
0.170
0.335
0.476
0.547
0.705
0.736
0.816
0.509
0.599
2.66
3.73
7.04
9.08
12.6
14.4
11.4
9.76
11.1
0.193
0.692
2.30
3.84
10.5
13.2
17.7
4.03
6.55
0.002
0.013
0.099
0.267
1.05
1.56
3.47
0.203
0.413
0.050
0.309
0.707
1.36
3.18
4.23
7.93
1.03
2.02
3.61
8.63
11.9
15.8
21.3
23.4
26.7
14.1
19.0
93.5
86.6
78.0
69.6
51.4
43.3
32.8
70.8
60.9
and slurry processes. The ethylene macromonomers, once generated, are incorporated into polymer chains to form branches before they diffuse out
of the active center reaction volume.
k 221
AOEOO
AOOO 1 E O
(15)
k 222
AOOO 1 O O
AOOOO
Penultimate Effect
In a copolymerization process, if the reactivity of
an active center is determined by both terminal
and penultimate units, the propagation reactions
should be written as
(16)
(17)
(18)
r 2p 5 k 222/k 221
(19)
(20)
k 111
AOEE 1 E O
AOEEE
(9)
k 112
AOEE 1 O O
AOOEE
(10)
k 211
AOEO 1 E O
AOEEO
(11)
k 212
AOOEO
AOEO 1 O O
(12)
k 121
AOOE 1 E O
AOEOE
(13)
k 122
AOOE 1 O O
AOOOE
(14)
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WANG ET AL.
Figure 5. Dependence of the triad distribution ratios on the monomer ratio of ethylene and octene-1 for a series of copolymerizations carried out with different monomer
ratios at 140C. (a) 2P(EEE)/P(OEE 1 EEO) versus (12f2)/f2 for the estimate of r 1p , (b)
P(OEE 1 EEO)/P(OEO) versus 2(1-f2)/f2 for the estimate of r91p (c) 2P(OOO)/P(OOE
1 EOO) versus f2/(12f2) for the estimate of r2 p, (d) P(OOE1EOO)/P(EOE) versus
2 f2/(12f2) for the estimate of r92p.
r 1p 5
2f 2P(EEE)
~1 2 f 2!P~OEE 1 EEO!
(21)
r91p 5
f 2P~OEE 1 EEO!
2~1 2 f 2!P~OEO)
(22)
r 2p 5
2~1 2 f 2!P~OOO!
f 2P~OOE 1 EOO!
(23)
r92p 5
~1 2 f 2!P~OOE 1 EOO!
2f 2P~EOE!
(24)
CONCLUSION
Ethylene and octene-1 copolymers with narrow
MWDs of about 2 and high octene-1 contents (octene-1 mole fraction up to F1 5 0.337) were produced with the CGC-Ti catalyst system using our
high-temperature
high-pressure
continuous
stirred-tank reactor. The CGC-Ti catalyst appeared to be a single site type for the copolymerization and showed high incorporation rates for
high a-olefin. The activity of CGC-Ti decreased
with increase in octene-1 concentration, particularly at high octene-1 concentration level. With
the increase of octene-1 feed ratio, the molecular
weight decreased and MWD also broadened. The
ethylene and octene-1 copolymerization with
CGC-Ti followed first-order Markov statistics.
The estimated reactivity ratios were r1 5 7.90 and
r2 5 0.099. The penultimate effect was also investigated using 13C-NMR measurements of triad
distributions. The reactivity ratios were r1p
5 10.6, r91p 5 7.39 for ethylene and r2p 5 0.088, r92p
5 0.175 for octene-1 terminal units, respectively.
These values demonstrated the existence of a minor penultimate effect in the ethylene/octene-1
copolymerization under the present experimental
conditions. It was also found that the value of
k12/k11 5 0.127 for the ethylene/ octene-1 system
is comparable to that of k12/k11 5 0.081 for the
ethylene/macromonomer system found in our pre-
2957