US20190374932A1 - Oxo-nitrogenated iron complex, catalytic system comprising said oxo-nitrogenated iron complex and process for the (co)polymerization of conjugated dienes - Google Patents

Oxo-nitrogenated iron complex, catalytic system comprising said oxo-nitrogenated iron complex and process for the (co)polymerization of conjugated dienes Download PDF

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US20190374932A1
US20190374932A1 US16/300,597 US201716300597A US2019374932A1 US 20190374932 A1 US20190374932 A1 US 20190374932A1 US 201716300597 A US201716300597 A US 201716300597A US 2019374932 A1 US2019374932 A1 US 2019374932A1
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polymerization
oxo
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aluminum
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Guido Pampaloni
Anna Sommazzi
Giovanni Ricci
Francesco Masi
Giuseppe Leone
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Versalis SpA
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    • C08F4/52—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides selected from boron, aluminium, gallium, indium, thallium or rare earths
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    • C08F4/70—Iron group metals, platinum group metals or compounds thereof
    • C08F4/7001—Iron group metals, platinum group metals or compounds thereof the metallic compound containing a multidentate ligand, i.e. a ligand capable of donating two or more pairs of electrons to form a coordinate or ionic bond
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    • C08F4/7081—Neutral ligand
    • C08F4/7083—ONNO
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    • B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
    • B01J2531/30—Complexes comprising metals of Group III (IIIA or IIIB) as the central metal
    • B01J2531/31—Aluminium
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    • B01J2531/80—Complexes comprising metals of Group VIII as the central metal
    • B01J2531/84—Metals of the iron group
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    • B01J2531/80—Complexes comprising metals of Group VIII as the central metal
    • B01J2531/84—Metals of the iron group
    • B01J2531/847—Nickel

Definitions

  • the present invention relates to an oxo-nitrogenated iron complex.
  • the present invention relates to an oxo-nitrogenated iron complex and to its use in a catalytic system for the (co)polymerization of conjugated dienes.
  • the present invention also relates to a catalytic system for the (co)polymerization of conjugated dienes comprising said oxo-nitrogenated iron complex.
  • the present invention relates to a (co)polymerization process of conjugated dienes, in particular, to a process for the polymerization of 1-3-butadiene or isoprene, characterized in that it uses said catalytic system.
  • 1,4-cis polybutadiene is prepared through polymerization processes that use different catalytic systems comprising catalysts based on titanium (Ti), cobalt (Co), nickel (Ni), neodymium (Nd).
  • Catalytic systems comprising cobalt based catalysts have high catalytic activity and stereospecificity and can be considered the most versatile of those mentioned above since, when by changing their formulation, they are able to provide all the possible stereoisomers of polybutadiene mentioned above, as described, for example, in: Porri L. et al., “ Comprehensive Polymer Science ” (1989), Eastmond G. C. et al. Eds., Pergamon Press, Oxford, UK, Vol. 4, Part II, pg.
  • Iron (Fe) based catalysts have also been studied which are useful in the (co)polymerization of conjugated dienes.
  • One of the first studies in literature on catalytic systems comprising iron (Fe) based catalysts concerned the (co)polymerization of 1,3-butadiene and isoprene with catalytic systems comprising iron acetylacetonate [Fe(acac) 3 ], tri-iso-butyl-aluminum (TIBA) and 1,10-phenanthroline (phen) as described, for example, in Zhang Z. Y. et al., “ Journal of Molecular Catalysis ” (1982), Vol. 17, Issue 1, pg. 65-76.
  • Said catalytic system is able to provide a binary polybutadiene with a mixed 1,4-cis/1,2 structure having an equal content of 1,4-cis and 1,2 units.
  • the active species in said catalytic system is likely to be constituted, as suggested by the authors, by an iron (II) complex [Fe(II)] formed by the reduction of iron acetylacetonate [Fe(acac)] through reaction with tri-iso-butyl-aluminum (TIBA), said iron (II) complex [Fe(II)] containing 1,10-phenanthroline (phen) as a ligand.
  • U.S. Pat. No. 6,160,063 describes a catalytic system obtained by combination or by reaction of: a compound containing iron (e.g., iron carboxylate, iron ⁇ -diketonate, iron alkoxide, iron arylalkoxide); an organic compound of magnesium; and a cyclic hydrogen phosphite.
  • a compound containing iron e.g., iron carboxylate, iron ⁇ -diketonate, iron alkoxide, iron arylalkoxide
  • an organic compound of magnesium e.g., magnesium phosphite
  • the aforementioned catalytic system is particularly useful for the polymerization of 1,3-butadiene for providing binary polybutadiene with a mixed 1,4-cis/1,2 structure.
  • U.S. Pat. No. 6,180,734 describes a catalytic system obtained by combination or by reaction of: a compound containing iron (e.g., iron carboxylate, iron 1-diketonate, iron alkoxide, iron arylalkoxide); cyclic hydrogen phosphite; and an organic compound of aluminum.
  • a compound containing iron e.g., iron carboxylate, iron 1-diketonate, iron alkoxide, iron arylalkoxide
  • cyclic hydrogen phosphite e.g., aluminum phosphite
  • U.S. Pat. No. 6,211,313 describes a catalytic system obtained by combination or by reaction of: a compound containing iron (e.g., iron carboxylate, iron ⁇ -diketonate, iron alkoxide, iron arylalkoxide); cyclic hydrogen phosphite; and an aluminoxane.
  • a compound containing iron e.g., iron carboxylate, iron ⁇ -diketonate, iron alkoxide, iron arylalkoxide
  • U.S. Pat. No. 6,277,779 describes a catalytic system obtained by combination or by reaction of: a compound containing iron (e.g., iron carboxylate, iron 9R-diketonate, iron alkoxide, iron arylalkoxide); a dihydrocarbyl hydrogen phosphite; and an organic compound of aluminum.
  • a compound containing iron e.g., iron carboxylate, iron 9R-diketonate, iron alkoxide, iron arylalkoxide
  • a dihydrocarbyl hydrogen phosphite e.g., aluminum phosphite
  • the aforementioned catalytic system is particularly useful for the polymerization of 1,3-butadiene for providing 1,2 syndiotactic polybutadiene having a melting point that can vary between 100° C. and 200° C., according to the components and the ratios between the different components present in said catalytic system.
  • U.S. Pat. Nos. 6,284,702 and 6,388,030 describe a catalytic system obtained by combination or by reaction of: a compound containing iron (e.g., iron carboxylate, iron ⁇ diketonate, iron alkoxide, iron arylalkoxide); an organic compound of magnesium; and a dihydrocarbyl hydrogen phosphite.
  • a compound containing iron e.g., iron carboxylate, iron ⁇ diketonate, iron alkoxide, iron arylalkoxide
  • an organic compound of magnesium e.g., magnesium
  • a dihydrocarbyl hydrogen phosphite e.g., magnesium phosphite.
  • the aforementioned catalytic system is particularly useful for the polymerization of 1,3-butadiene for providing 1,2 syndiotactic polybutadiene having a melting point that can vary between 100° C. and 190° C., according to the components and the ratios
  • Catalytic systems comprising, for example, iron diethyl bis(2,2′-bipyridine) [(Bipy) 2 FeEt 2 ] and methylaluminoxane (MAO), or comprising various iron dichloride (FeCl 2 ) complexes with bidentate aromatic amines (e.g., N,N,N′,N′-tetramethylethylenediamine (tmeda), N,N′-dimethylethylenediamine (dmeda), 2,2′-bipyridine (bipy), 1,10-phenanthroline (phen), and compounds of aluminum [e.g., aluminum alkyls (AlR 3 wherein R is ethyl, iso-butyl), methylaluminoxane (MAO)], are extremely active in the (co)polymerization of conjugated dienes, as described, for example, in international patent application WO 02/102861; or in Bazzini C.
  • AlR 3 aluminum alkyls
  • Such catalytic systems are able to provide polybutadienes with a prevalently 1,2 structure; in particular, the polybutadienes obtained at low temperatures have an approximately 90% 1,2 structure and a 50% syndiotactic pentade structure, and the 1,2 unit and syndiotactic pentade contents are reduced as the polymerization temperature increases.
  • M w weight-average molecular weight
  • PDI polydispersion index
  • the type of aluminum compound can also affect the catalytic activity: in fact, it has been observed that when methylaluminoxane (MAO) is used, there is an increase in the 1,2 unit content under the same polymerization conditions.
  • MAO methylaluminoxane
  • the aforementioned catalytic systems were shown to be extremely active and selective not only in the polymerization of 1,3-butadiene but also in the (co)polymerization of other conjugated dienes such as, for example, isoprene, 2,3-dimethyl-1,3-butadiene, 3-methyl-1,3-pentadiene, providing (co)polymers with different structures such as, for example, syndiotactic 3,4 polyisoprene, 1,4-cis poly(2,3-dimethyl-1,3-butadiene), syndiotactic E-1,2-poly(3-methyl-1,3-pentadiene).
  • Catalytic systems comprising iron ter-pyridine complexes [e.g., FeCl 3 (ter-pyridine)], in combination with appropriate alkylating agents, are useful in the stereospecific polymerization of conjugated dienes: said catalytic systems show discrete catalytic activity and are able to provide polybutadienes with a 1,4-trans structure as described, for example, in Nakayama Y. et al., “Macromolecules” (2003), Vol. 36(21), pg. 7953-7958.
  • Catalytic systems obtained through the combination of iron (III) carboxylates (e.g., iron (Ill) 2-ethylhexanoate [Fe(2-EHA) 3 ]Fe(III) with aluminum tri-iso-butyl (Al I Bu 3 ) in hexane, in the presence of phosphates (e.g., triethylphosphate) are able to polymerize 1,3-butadiene to polybutadiene with a prevalently 1,2 structure and with a high degree of syndiotacticity as described, for example, in Gong D. et al., “ Polymer ” (2009), Vol. 50, pg. 5980-5986.
  • Catalytic systems comprising complexes obtained from iron trichloride (FeCl 3 ) or from iron dichloride tetrahydrate (FeCl 2 .4H 2 O) with substituted 2,6-bis[1-(iminophenyl)ethyl]pyridine or 2,6-bis(imino)pyridine, in the presence of methylaluminoxane (MAO), are able to provide high 1,4-trans structure (>90%), or 1,4-cis/1,4-trans mixed structure polybutadienes, as a function of the catalytic system used as described, for example, in Gong D. et al., “ Polymer ” (2009), Vol. 50, pg. 6259-6264; Gong D. et al., “ Inorganic Chimica Acta ” (2011), Vol. 373, Issue 1, pg. 47-53.
  • Catalytic systems comprising complexes obtained from iron trichloride (FeCl 3 ) or from iron dichloride tetrahydrate (FeCl 2 .4H 2 O) with substituted 2,6-bis[1-(2-benzimidazolyl)]pyridine or 2,6-bis(pyrazol)pyridine, in the presence of modified methylaluminoxane (MMAO) or diethylaluminum chloride (AlEt 2 Cl), are able to provide polybutadienes with a different structure, i.e. 1,4-trans or 1,4-cis, as a function of the catalytic system used as described, for example, in Gong D. et al., “ Journal of Organometallic Chemistry ” (2012), Vol. 702, pg. 10-18.
  • MMAO modified methylaluminoxane
  • AlEt 2 Cl diethylaluminum chloride
  • Bis-imine complexes of iron (II) [Fe(II] with pincer ligands in combination with aluminum alkyl [for example, tri-methylaluminum (AlMe 3 ) are able to provide polybutadienes with an essentially 1,4-cis structure ( ⁇ 70%) as described, for example, in Zhang J. et al., “ Dalton Transactions ” (2012), Vol. 41, pg. 9639-9645.
  • Catalytic systems comprising bis-imine-pyridine complexes of iron, aluminum alkyls (e.g., AlR 3 wherein R is ethyl, iso-butyl), and boron salts, are able to polymerize isoprene to polyisoprene with a high 1,4-trans structure as described, for example, in Raynaud J. et al., “ Angewandte Chemie International Edition ” (2012), Vol. 51, pg. 11805-11808.
  • Catalytic systems comprising iron (II) complexes with substituted 2-pyrazolyl-1,10-phenanthroline and aluminum alkyls (e.g., AlR 3 wherein R is ethyl, iso-butyl, octyl), are characterized by a high and selective catalytic level and are able to provide polybutadienes with a high 1,4-trans structure as described, for example, in Wang B. et al., “ Polymer ” (2013), Vol. 54, pg. 5174-5181.
  • Catalytic systems comprising iron (II) complexes with 2-(N-arylcarboxyimidoylchloride)quinoline and aluminum alkyls [e.g., AlR 3 wherein R is ethyl, iso-butyl; or methylaluminoxane (MAO)], are characterized by low catalytic activity and are able to provide polybutadienes with a high 1,4-cis structure as described, for example, in Liu H. et al., “ Journal of Molecular Catalysis A: Chemical ” (2014), Vol. 391, pg. 25-35.
  • Catalytic systems comprising iron (II) complexes with 2,6-bis(dimethyl-2-oxazoline-2-yl)pyridine and aluminum alkyls [e.g., AlR 3 wherein R is ethyl, iso-butyl; or methylaluminoxane (MAO)], are able to provide polybutadienes with a mixed 1,4-cis/1,4-trans structure as described, for example, in Gong D. et al., “ Journal of Molecular Catalysis A: Chemical ” (2015), Vol. 406, pg. 78-84.
  • polybutadienes with “soft/hard” stereoblocks, with a mixed 1,4-cis/1,2 structure were obtained using the catalytic system 2-ethylhexanoate of iron/tri-iso-butylaluminum/diethyl phosphate [Fe(2-EHA) 3 /Al I Bu) 3 /DEP], appropriately varying the aluminum/iron (Al/Fe) ratio as described, for example, in Zheng W. et al., “ Journal of Polymer Science Part A: Polymer Chemistry ” (2015), Vol. 53, Issue 10, pg. 1182-1188.
  • the Applicant has considered the problem of finding a new oxo-nitrogenated iron complex to be used in a catalytic system able to provide (co)polymers of conjugated dienes, such as, for example, linear or branched polybutadiene or linear or branched polyisoprene, with a mixed structure, in particular, polybutadiene with a prevalent 1,4-cis and 1,2 unit content (i.e. having a content of 1,4-cis and 1,2 units ⁇ 90%, preferably equal to 100%), and polyisoprene with a prevalent content of 1,4-cis and 3,4 units (i.e. having a content of 1,4-cis and 3,4 units ⁇ 90%, preferably equal to 100%).
  • conjugated dienes such as, for example, linear or branched polybutadiene or linear or branched polyisoprene
  • a mixed structure in particular, polybutadiene with a prevalent 1,4-cis and 1,2 unit content (i.e
  • the Applicant has now found a new oxo-nitrogenated iron complex having general formula (I) or (II) below defined, able to provide (co)polymers of conjugated dienes, such as, for example, linear or branched polybutadiene or polyisoprene, with a mixed structure, in particular, polybutadiene with a prevalent 1,4-cis and 1,2 unit content (i.e. having a content of 1,4-cis and 1,2 units 90%, preferably equal to 100%), and polyisoprene with a prevalent content of 1,4-cis and 3,4 units (i.e. having a content of 1,4-cis and 3,4 units 90%, preferably equal to 100%).
  • conjugated dienes such as, for example, linear or branched polybutadiene or polyisoprene
  • a mixed structure in particular, polybutadiene with a prevalent 1,4-cis and 1,2 unit content (i.e. having a content of 1,4-cis and 1,2 units
  • C 1 -C 20 alkyl groups means alkyl groups having from 1 to 20 carbon atoms, linear or branched.
  • C 1 -C 20 alkyl groups are: methyl, ethyl, n-propyl, iso-propyl, n-butyl, s-butyl, iso-butyl, tert-butyl, pentyl, hexyl, heptyl, octyl, n-nonyl, n-decyl, 2-butyloctyl, 5-methylhexyl, 4-ethylhexyl, 2-ethylheptyl, 2-ethylhexyl.
  • halogenated C 1 -C 20 alkyl groups means alkyl groups having from 1 to 20 carbon atoms, linear or branched, saturated or unsaturated, wherein at least one of the hydrogen atoms is substituted with a halogen atom such as, for example, fluorine, chlorine, bromine, preferably fluorine, chlorine.
  • C 1 -C 20 alkyl groups optionally containing halogenated are: fluoromethyl, difluoromethyl, trifluoromethyl, trichloromethyl, 2,2,2-trifluoroethyl, 2,2,2-trichloroethyl, 2,2,3,3-tetrafluoropropyl, 2,2,3,3,3-pentafluoropropyl, perfluoropentyl, perfluoroctyl, perfluorodecyl.
  • cycloalkyl groups means cycloalkyl groups having from 3 to 30 carbon atoms. Said cycloalkyl groups can be optionally substituted with one or more groups, identical or different, selected from: halogen atoms; hydroxyl groups, C 1 -C 12 alkyl groups; C 1 -C 12 alkoxy groups; cyano groups; amino groups; nitro groups.
  • cycloalkyl groups are: cyclopropyl, 2,2-difluorocyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, hexamethylcyclohexyl, pentamethlylcyclopentyl, 2-cyclooctylethyl, methylcyclohexyl, methoxycyclohexyl, fluorocyclohexyl, phenylcyclohexyl.
  • aryl groups means carbocyclic aromatic groups.
  • Said carbocyclic aromatic groups can be optionally substituted with one or more groups, identical or different, selected from: halogen atoms such as, for example, fluorine, chlorine, bromine; hydroxyl groups, C 1 -C 12 alkyl groups; C 1 -C 12 alkoxy groups; cyano groups; amino groups; nitro groups.
  • aryl groups are: phenyl, 2-methylphenyl, 4-methylphenyl, 2,4,6-trimethylphenyl, 2,6-di-iso-propylphenyl, methoxyphenyl, hydroxyphenyl, phenyloxyphenyl, fluorophenyl, pentafluorophenyl, chlorophenyl, bromophenyl, nitrophenyl, dimethylaminophenyl, naphthyl, phenylnaphthyl, phenanthrene, anthracene.
  • the oxo-nitrogenated iron complex having general formula (I) or (II) can be considered, in accordance with the present invention, under any physical form such as, for example, the isolated and purified solid form, the form solvated with an appropriate solvent, or the one supported on suitable organic or inorganic solids, preferably having a granular or powdered physical form.
  • the oxo-nitrogenated iron complex having general formula (I) or (II) is prepared starting from ligands known in the prior art.
  • ligands useful for the purpose of the present invention are those having the following formulae (L1)-(L5):
  • Said ligands having formulae (L1)-(L5) can be prepared through processes known in the prior art.
  • said ligands having formulae (L1)-(L5) can be prepared through condensation reactions between primary amines and diketones as described, for example, in international patent application WO 2013/037911 in the name of the Applicant; or by: Parks J. E. and Holm R. H. in “ Inorganic Chemistry ” (1968), Vol 7(7), pg. 1408-1416; Roberts E. and Turner E. E. in “ Journal of Chemical Society ” (1927), pg. 1832-1857; Dudek G. O. and Holm R. H. in “ Journal of the American Chemical Society ” (1961), Vol. 83, Issue 9, pg. 2099-2104. More details on the process for the preparation of said ligands having formulae (L1)-(L5) can be found in the following examples.
  • the oxo-nitrogenated iron complex having general formula (I) or (II) can be prepared according to processes known in the prior art.
  • said oxo-nitrogenated iron complex can be prepared by reaction between iron compounds having general formula Fe(X) 2 or Fe(X) 3 wherein X is a halogen atom such as, for example, chlorine, bromine, iodine, preferably chlorine, as it is or complexed with ethers [e.g., diethylether, tetrahydrofuran (THF), dimethoxyethane], or with water, with the ligands having formulae (L1)-(L5) reported above, in molar ratio ligand (L)/iron (Fe) ranging from 1 to 2 operating, preferably, in the presence of at least one solvent which can be selected, for example, from: chlorinated solvents (e.g., methylene chloride), ether solvents, [e.g., tetrahydrofuran (THF)
  • said ligands having formulae (L1)-(L5), prior to the reaction with the aforementioned iron compounds having general formula Fe(X) 2 or Fe(X) 3 wherein X has the meanings mentioned above, can be made to react with a solution of an alkyllithium (e.g., n-butyllithium) in a hydrocarbon solvent (e.g., hexane).
  • an alkyllithium e.g., n-butyllithium
  • a hydrocarbon solvent e.g., hexane
  • the oxo-nitrogenated iron complex thus obtained can be subsequently recovered through known methods such as, evaporation of the solvent (e.g., under vacuum), followed by solubilization in an appropriate solvent, subsequent filtration (e.g., on Celite®) followed by drying (e.g., under vacuum). More details on the process for the preparation of said oxo-nitrogenated iron complex having general formula (I) or (II) can be found in the following examples.
  • ambient temperature means a temperature ranging from 20° C. to 25° C.
  • the present invention also relates to a catalytic system for the (co)polymerization of conjugated dienes comprising said oxo-nitrogenated iron complex having general formula (I) or (II).
  • the present invention also relates to a catalytic system for the (co)polymerization of conjugated dienes comprising:
  • the formation of the catalytic system comprising the oxo-nitrogenated iron complex having general formula (I) or (II) and the co-catalyst (b), is preferably performed in an inert liquid medium, more preferably in a hydrocarbon solvent.
  • the choice of the oxo-nitrogenated iron complex having general formula (I) or (II) and of the co-catalyst (b), as well as the particular methodology used, can vary according to the molecular structures and to the desired result, according to what is similarly reported in relevant literature accessible to an expert skilled in the art for other transition metal complexes with imine ligands, as reported, for example, by L. K.
  • said co-catalyst (b) can be selected from (b 1 ) aluminum alkyls having general formula (III):
  • X′ represents a halogen atom such as, for example, chlorine, bromine, iodine, fluorine
  • R 5 is selected from linear or branched C 1 -C 20 alkyl groups, cycloalkyl groups, aryl groups, said groups being optionally substituted with one or more atoms of silicon or germanium
  • n is an integer ranging from 0 to 2.
  • said co-catalyst (b) can be selected from (b 2 ) organo-oxygenated compounds of an element M′ different from carbon belonging to groups 13 or 14 of the Periodic Table of the Elements, preferably organo-oxygenated compounds of aluminum, gallium, tin.
  • Said organo-oxygenated compounds (b 2 ) can be defined as organic compounds of M′, wherein the latter is bonded to at least one oxygen atom and to at least one organic group comprising an alkyl group having from 1 to 6 carbon atoms, preferably methyl.
  • said co-catalyst (b) can be selected from (b 3 ) compounds or mixtures of organometallic compounds of an element M′ different from carbon able to react with the oxo-nitrogenated iron complex having general formula (I) or (II) by extracting from it a ⁇ -linked substituent X 1 or X 2 , to form on the one hand at least one neutral compound and, on the other hand, an ionic compound consisting of a cation containing the metal (Fe) coordinated by the ligand, and a non-coordinating organic anion containing the metal M′, whose negative charge is delocalized on a multicentric structure.
  • Periodic Table of the Elements refers to the “IUPAC Periodic Table of the Elements”, version dated 1 Jun. 2012, available on the following website: www.iupac.org/fileadmin/user upload/news/IUPAC Periodic Table-1Jun12.pdf.
  • aluminum alkyls having general formula (III) particularly useful for the purpose of the present invention are: tri-methyl-aluminum, tri-(2,3,3-tri-methyl-butyl)-aluminum, tri-(2,3-di-methyl-hexyl)-aluminum, tri-(2,3-di-methyl-butyl)-aluminum, tri-(2,3-di-methyl-pentyl)-aluminum, tri-(2,3-di-methyl-heptyl)-aluminum, tri-(2-methyl-3-ethyl-pentyl)-aluminum, tri-(2-methyl-3-ethyl-hexyl)-aluminum, tri-(2-methyl-3-ethyl-heptyl)-aluminum, tri-(2-methyl-3-propyl-hexyl)-aluminum, tri-ethyl-aluminum, tri-(2-ethyl-3-
  • the aluminum alkyls having general formula (III) when used for the formation of a catalytic (co)polymerization system in accordance with the present invention, can be placed in contact with an oxo-nitrogenated iron complex having general formula (i) or (II), in proportions such that the molar ratio between the aluminum contained in the aluminum alkyls having general formula (III) and the iron contained in the oxo-nitrogenated iron complex having general formula (I) or (II) can be ranging from 5 to 5000, preferably ranging from 10 to 1000.
  • the sequence with which the oxo-nitrogenated iron complex having general formula (I) or (II) and the aluminum alkyl having general formula (III) are placed in contact with each other is not particularly critical.
  • said organo-oxygenated compounds (b 2 ) can be selected from the aluminoxanes having general formula (IV):
  • R 9 , R 7 and R 8 identical or different, represent a hydrogen atom, a halogen atom such as, for example, chlorine, bromine, iodine, fluorine; or are selected from C 1 -C 20 alkyl groups, linear or branched, cycloalkyl groups, aryl groups, said groups being optionally substituted with one or more atoms of silicon or germanium; and p is an integer ranging from 0 to 1000.
  • aluminoxanes are compounds containing Al—O—Al bonds, with a variable O/Al ratio, obtainable according to processes known in the prior art such as, for example, by reaction, in controlled conditions, of an aluminum alkyl, or of an aluminum alkyl halogenide, with water, or with other compounds containing predetermined quantities of available water such as, for example, in the case of the reaction of aluminum trimethyl with aluminum sulfate hexahydrate, copper sulfate pentahydrate, or iron sulfate pentahydrate.
  • Said aluminoxanes and, in particular, methylaluminoxane (MAO) are compounds that can be obtained through known organometallic chemical processes such as, for example, by adding trimethyl aluminum to a suspension in aluminum sulfate hexahydrate.
  • the aluminoxanes having general formula (IV) when used for the formation of a catalytic (co)polymerization system in accordance with the present invention, can be placed in contact with an oxo-nitrogenated iron complex having general formula (I) or (II), in proportions such that the molar ratio between the aluminum (Al) contained in the aluminoxane having general formula (IV) and the iron contained in the oxo-nitrogenated iron complex having general formula (I) or (II) is ranging from 10 to 10000, preferably ranging from 100 to 5000.
  • the sequence with which the oxo-nitrogenated iron complex having general formula (I) or (II) and the aluminoxane having general formula (IV) are placed in contact with each other is not particularly critical.
  • the definition of the compound (b 2 ) in accordance with the present invention also includes galloxanes wherein, in the general formula (IV), gallium is contained in the place of aluminum and stannoxanes wherein, in the general formula (IV), tin is contained in the place of aluminum, whose use as co-catalysts for the polymerization of olefins in the presence of metallocene complexes is known. Further details in relation to said galloxanes and stannoxanes can be found, for example, in the U.S. Pat. Nos. 5,128,295 and 5,258,475.
  • aluminoxanes having general formula (IV) particularly useful for the purpose of the present invention are: methylaluminoxane (MAO), ethyl-aluminoxane, n-butyl-aluminoxane, tetra-iso-butyl-aluminoxane (TIBAO), tert-butyl-aluminoxane, tetra-(2,4,4-tri-methyl-pentyl)-aluminoxane (TIOAO), tetra-(2,3-di-methyl-butyl)-aluminoxane (TDMBAO), tetra-(2,3,3-tri-methyl-butyl)-aluminoxane (TTMBAO).
  • Methylaluminoxane (MAO) is particularly preferred.
  • said compounds or mixtures of compounds (b 3 ) can be selected from organic compounds of aluminum and especially of boron, such as, for example, those represented by the following general formulae:
  • each R C group independently represents an alkyl group or an aryl group having from 1 to 10 carbon atoms and each RD group independently represents an aryl group partially or totally, preferably totally, fluorinated, having from 6 to 20 carbon atoms, Pyr is a pyrrole radical, optionally substituted.
  • the compounds or mixtures of compounds (b 3 ) when used for the formation of a catalytic (co)polymerization system in accordance with the present invention, can be placed in contact with an oxo-nitrogenated iron complex having general formula (I) or (II), in proportions such that the molar ratio between the metal (M′) contained in the compounds or mixtures of compounds (b 3 ) and the iron contained in the oxo-nitrogenated iron complex having general formula (I) or (II) is ranging from 0.1 to 15, preferably ranging from 0.5 to 10, more preferably ranging from 1 to 6.
  • the sequence with which the oxo-nitrogenated iron complex having general formula (I) or (II) and the compound or mixture of compounds (b 3 ) are placed in contact with each other is not particularly critical.
  • Said compounds or mixtures of compounds (b 3 ), especially in the case wherein X, and X 2 in the oxo-nitrogenated iron complex having general formula (I) or (II) are different from alkyl, must be used in combination with an aluminoxane having general formula (IV) such as, for example, methylaluminoxane (MAO), or, preferably, with an aluminum alkyl having general formula (II), more preferably a trialkylaluminum having from 1 to 8 carbon atoms in each alkyl residue, such as, for example, tri-methyl-aluminum, tri-ethyl-aluminum, tri-iso-butylaluminum (TIBA).
  • an aluminoxane having general formula (IV) such as, for example
  • tributylammonium-tetrakis-pentafluorophenyl-borate tributylammonium-tetrakis-pentafluorophenyl-aluminate
  • tributylammonium-tetrakis-[(3,5-di-(trifluorophenyl)]-borate tributylammonium-tetrakis-(4-fluorophenyl)]-borate
  • N,N-dimethylbenzylammonium-tetrakis-pentafluoro-phenyl-borate N,N-dimethyl-hexylammonium-tetrakis-pentafluorophenyl-borate
  • N, N-dimethylanilinium-tetrakis-(pentafluorophenyl)-borate N, N-N-
  • the terms “mole” and “molar ratio” are used both with reference to compounds consisting of molecules and with reference to atoms and ions, omitting for the latter ones the terms gram atom or atomic ratio, even if they are scientifically more accurate.
  • Additives and/or components that can be added in the preparation and/or formulation of the catalytic system according to the present invention are, for example: inert solvents, such as, for example, aliphatic and/or aromatic hydrocarbons; aliphatic and/or aromatic ethers; weakly coordinating additives (e.g., Lewis bases) selected, for example, from non-polymerizable olefins; sterically hindered or electronically poor ethers; halogenating agents such as, for example, silicon halides, halogenated hydrocarbons, preferably chlorinated; or mixtures thereof.
  • inert solvents such as, for example, aliphatic and/or aromatic hydrocarbons
  • aliphatic and/or aromatic ethers aliphatic and/or aromatic ethers
  • weakly coordinating additives e.g., Lewis bases
  • halogenating agents such as, for example, silicon halides, halogenated hydrocarbons, preferably chlorinated; or mixtures thereof.
  • Said catalytic system can be prepared, as already reported above, according to methods known in the prior art.
  • said catalytic system can be prepared separately (preformed) and subsequently introduced into the (co)polymerization environment.
  • said catalytic system can be prepared by making at least one oxo-nitrogenated iron complex (a) having general formula (I) or (II) react with at least one co-catalyst (b), possibly in presence of other additives or components selected from those cited above, in the presence of a solvent such as, for example, toluene, heptane, at a temperature ranging from 20° C. to 60° C., for a time ranging from 10 seconds to 10 hours, preferably ranging from 30 seconds to 5 hours. Further details on the preparation of said catalytic system can be found in the examples reported below.
  • said catalytic system can be prepared in situ, i.e. directly in the (co)polymerization environment.
  • said catalytic system can be prepared by separately introducing the oxo-nitrogenated iron complex (a) having general formula (I) or (II), the co-catalyst (b) and the pre-selected conjugated diene(s) to be (co)polymerized, operating at the conditions wherein the (co)polymerization is performed.
  • the aforementioned catalytic systems can also be supported on inert solids, preferably constituted by silicon and/or aluminum oxides, such as, for example, silica, alumina or silico-aluminates.
  • inert solids preferably constituted by silicon and/or aluminum oxides, such as, for example, silica, alumina or silico-aluminates.
  • the known supporting techniques can be used, generally comprising contact, in a suitable inert liquid medium, between the support, optionally activated by heating to temperatures over 200° C., and one or both components (a) and (b) of the catalytic system according to the present invention.
  • the scope of the present invention also includes the oxo-nitrogenated iron complex having general formula (I) or (II), and the catalytic systems based thereon, which are supported on a solid through the functionalization of the latter and the formation of a covalent bond between the solid and the oxo-nitrogenated iron complex having general formula (I) or (II).
  • the present invention relates to a (co)polymerization process of conjugated dienes, characterized in that it uses said catalytic system.
  • the quantity of oxo-nitrogenated iron complex (a) having general formula (I) or (II) and of co-catalyst (b) which can be used in the (co)polymerization of conjugated dienes varies according to the (co)polymerization process to be performed.
  • Said quantity is however such as to obtain a molar ratio between the iron contained in the oxo-nitrogenated iron complex having general formula (I) or (II) and the metal contained in the co-catalyst (b), e.g., aluminum in the case wherein the co-catalyst (b) is selected from the aluminum alkyls (b 1 ) or from the aluminoxanes (b 2 ), boron in the case wherein the co-catalyst (b) is selected from the compounds or mixtures of compounds (b 3 ) having general formula (IV), comprised between the values reported above.
  • Preferred (co)polymerizable conjugated dienes are 1,3-butadiene, isoprene.
  • the aforementioned (co)polymerizable conjugated dienes can be used alone, or in a mixture of two or more dienes. In this latter case, i.e. using a mixture of two or more dienes, a copolymer will be obtained.
  • the present invention relates to a polymerization process of 1,3-butadiene or isoprene, characterized in that it uses said catalytic system.
  • said (co)polymerization can be performed in the presence of a polymerization solvent, generally selected from inert organic solvents, such as, for example: saturated aliphatic hydrocarbons such as, for example, butane, pentane, hexane, heptane, or mixtures thereof; saturated cyclo-aliphatic hydrocarbons such as, for example, cyclopentane, cyclohexane, or mixtures thereof; mono-olefins such as, for example, 1-butene, 2-butene, or mixtures thereof; aromatic hydrocarbons such as, for example, benzene, toluene, xylene, or mixtures thereof; halogenated hydrocarbons such as, for example, methylene chloride, chloroform, carbon tetrachloride, trichloroethylene, perchloroethylene, 1,2-dichloroethane, chlorobenzene, bromobenzene, chlorotoluene, or mixture
  • said (co)polymerization can be performed using as a (co)polymerization solvent the same conjugated diene(s) that must be (co)polymerized, in accordance with the process known as “bulk process”.
  • the concentration of the conjugated diene to be (co)polymerized in said (co)polymerization solvent is ranging from 5% by weight to 50% by weight, preferably ranging from 10% by weight to 20% by weight, with respect to the total weight of the conjugated diene mixture and inert organic solvent.
  • said (co)polymerization can be performed at a temperature ranging from ⁇ 70° C. to +100° C., preferably ranging from ⁇ 20° C. to +80° C.
  • Said (co)polymerization can be performed both continuously and batchwise.
  • said process allows (co)polymers of conjugated dienes to be obtained, such as, polybutadiene, polyisoprene, in particular polybutadiene, linear or branched, with a mixed structure, in particular, polybutadiene with a prevalent 1,4-cis and 1,2 unit content (i.e. having a content of 1,4-cis and 1,2 units 90%, preferably equal to 100%), and polyisoprene with a prevalent content of 1,4-cis and 3,4 units (i.e. having a content of 1,4-cis and 3,4 units ⁇ 90%, preferably equal to 100%).
  • the mixture thus obtained was cooled to ambient temperature (20° C.-25° C.) and 1 ml of 70% nitric acid (HNO 3 ) was added, then it was left again until fumes appeared. After repeating the sequence another two times, a clear, almost colorless, solution was obtained. 1 ml of nitric acid (HNO 3 ) and about 15 ml of water were then added cold, then heated to 80° C. for about 30 minutes.
  • the sample thus prepared was diluted with MilliQ pure water until it weighed about 50 g, precisely weighed, to obtain a solution on which the instrumental analytical determination was performed using a Thermo Optek IRIS Advantage Duo ICP-OES (plasma optical emission) spectrometer, for comparison with solutions of known concentration. For this purpose, for every analyte, a calibration curve was prepared in the range 0 ppm-10 ppm, measuring calibration solutions by dilution by weight of certified solutions.
  • samples of the oxo-nitrogenated iron complexes object of the present invention about 30 mg-50 mg, were precisely weighed in 100 ml glass beakers in dry-box under nitrogen flow. 2 g of sodium carbonate (Na 2 CO 3 ) were added and, outside the dry-box, 50 ml of MilliQ water. It was brought to the boil on the hot plate, under magnetic stirring, for about 30 minutes. It was left to cool, then 1/5 diluted sulfuric acid (H 2 SO 4 ) was added, until acid reaction and was then titrated with 0.1 N silver nitrate (AgNO 3 ) with a potentiometric titrator.
  • Na 2 CO 3 sodium carbonate
  • MilliQ water 50 ml
  • H 2 SO 4 1/5 diluted sulfuric acid
  • the 13 C-HMR and 1 H-HMR spectra were recorded using a nuclear magnetic resonance spectrometer mod.
  • Bruker Avance 400 using deuterated tetrachloroethylene (C 2 D 2 Cl 4 ) at 103° C., and hexamethyldisiloxane (HDMS) as internal standard, or using deuterated chloroform (CDCl 3 ), at 25° C., and tetramethylsilane (TMS) as internal standard.
  • polymeric solutions were used with concentrations equal to 10% by weight with respect to the total weight of the polymeric solution.
  • the microstructure of the polymers [i.e. 1,4-cis (%) 1,4-trans (%) and 1,2(%) unit content for polybutadiene and 1,4-cis (%), 1,4-trans (%) and 3,4(%) unit content for polyisoprene] was determined through the analysis of the aforementioned spectra based on what is reported in literature by Mochel, V. D., in “ Journal of Polymer Science Part A -1: Polymer Chemistry ” (1972), Vol. 10, Issue 4, pg. 1009-1018 for polybutadiene, and by Sato H. et al. in “ Journal of Polymer Science: Polymer Chemistry Edition ” (1979), Vol. 17, Issue 11, pg. 3551-3558, for polyisoprene.
  • the FT-IR spectra (solid state-UATR) were recorded using a Bruker IFS 48 spectrophotometer equipped with a Thermo Spectra-Tech horizontal ATR connection.
  • the section wherein the samples to be analyzed are placed is a Fresnel ATR accessory (Shelton, Conn., USA) which uses crystals of zirconium selenide (ZnSe) with an angle of incidence of 45° in the horizontal direction.
  • Fresnel ATR accessory Shelton, Conn., USA
  • ZnSe zirconium selenide
  • the FT-IR spectra (solid state-UATR) of the oxo-nitrogenated iron complexes object of the present invention were obtained by inserting samples of the oxo-nitrogenated iron complex to be analyzed into said section.
  • the I.R. (FT-IR) spectra were recorded through Thermo Nicolet Nexus 670 and Bruker IFS 48 spectrophotometers.
  • the I.R. (FT-IR) spectra of the ligands used for the purpose of the present invention were obtained by dispersing the ligand to be analyzed in anhydrous potassium bromide (KBr) (KBr disks), or in Nujol solution.
  • the I.R. (FT-IR) spectra of the polymers were obtained from polymeric films on potassium bromide (KBr) tablets, said films being obtained through the deposition of a solution in hot 1,2-dichlorobenzene of the polymer to be analyzed.
  • concentration of the polymeric solutions analyzed was equal to 10% by weight with respect to the total weight of the polymeric solution.
  • MW molecular weight
  • M w weight-average molecular weight
  • PDI Polydispersion Index
  • the mass spectra of the ligands used for the purpose of the present invention were performed with a Trace DSQ single quadrupole mass spectrometer (Thermo ISQ) in Electronic Ionization (El mode), operating under the following conditions:
  • FIG. 1 shows the FT-IR spectrum (solid state-UATR) of the complex FeC 2 (L1) obtained.
  • FIG. 2 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L1) 2 obtained.
  • FIG. 3 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L2) obtained.
  • FIG. 4 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L2) 2 obtained.
  • FIG. 5 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L3) obtained.
  • FIG. 6 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L3) 2 obtained.
  • FIG. 7 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L4) obtained.
  • FIG. 8 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L4) 2 obtained.
  • FIG. 9 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L5) obtained.
  • FIG. 10 shows the FT-IR spectrum (solid state-UATR) of the complex FeCl 2 (L5) 2 obtained.
  • FIG. 11 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 12 shows the GPC (“Gel Permeation Chromatography”) curve of the polybutadiene obtained.
  • FIG. 13 shows the 1 H-NMR (top) and 13 C-NMR (bottom) spectra of the polybutadiene obtained.
  • FIG. 14 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 15 shows the GPC (“Gel Permeation Chromatography”) curve of the polybutadiene obtained.
  • FIG. 16 shows the 1 H-NMR (top) and 13 C-NMR (bottom) spectra of the polybutadiene obtained.
  • Example MG110 methylaluminoxane (MAO) in toluene solution (3.15 ml; 5 ⁇ 10 ⁇ 3 moles, equal to about 0.29 g) was added and, subsequently, the FeCl 2 (L1) 2 complex [sample MG110] (2.4 ml of toluene solution at a concentration equal 2 mg/ml; 1 ⁇ 10 ⁇ 5 moles, equal to about 4.8 mg) obtained as described in Example 7. The whole was kept under magnetic stirring, at ⁇ 50° C., for 120 minutes. The polymerization was then stopped by adding 2 ml of methanol containing some drops of hydrochloric acid.
  • MAO methylaluminoxane
  • the polymer obtained was then coagulated by adding 40 ml of a methanol solution containing 4% of Irganox 1076 antioxidant (Ciba) obtaining 0.456 g of polybutadiene having a mixed 1,4-cis/1,2 structure: further characteristics of the process and of the polybutadiene obtained are reported in Table 1.
  • FIG. 17 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 18 shows the FT-R spectrum of the polybutadiene obtained.
  • FIG. 19 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 20 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 21 shows the 1 H-NMR (top) and 13 C-NMR (bottom) spectra of the polybutadiene obtained.
  • FIG. 22 shows the FT-IR spectrum of the polybutadiene obtained.
  • the whole was kept under magnetic stirring, at ambient temperature, for 180 minutes.
  • the polymerization was then stopped by adding 2 ml of methanol containing some drops of hydrochloric acid.
  • the polymer obtained was then coagulated by adding 40 ml of a methanol solution containing 4% of Irganox® 1076 antioxidant (Ciba) obtaining 0.561 g of polybutadiene having a mixed 1,4-cis/1,4-trans/1,2 structure: further characteristics of the process and of the polybutadiene obtained are reported in Table 1.
  • FIG. 23 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 24 shows the GPC (“Gel Permeation Chromatography”) curve of the polybutadiene obtained.
  • FIG. 25 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 26 shows the FT-IR spectrum of the polybutadiene obtained.
  • FIG. 27 shows the 1 H-NMR (top) and 13 C-NMR (bottom) spectra of the polybutadiene obtained.
  • the polymerization was then stopped by adding 2 ml of methanol containing some drops of hydrochloric acid.
  • the polymer obtained was then coagulated by adding 40 ml of a methanol solution containing 4% of Irganox 1076 antioxidant (Ciba) obtaining 0.553 g of polyisoprene having a mixed 1,4-cis/3,4 structure: further characteristics of the process and of the polyisoprene obtained are reported in Table 2.
  • FIG. 28 shows the FT-IR spectrum of the polyisoprene obtained.
  • Example MG145 3.2 ml of toluene at a concentration equal to 2 mg/ml; 1 ⁇ 10 ⁇ 5 moles, equal to about 6.4 mg
  • the polymerization was then stopped by adding 2 ml of methanol containing some drops of hydrochloric acid.
  • the polymer obtained was then coagulated by adding 40 ml of a methanol solution containing 4% of Irganox® 1076 antioxidant (Ciba) obtaining 0.502 g of polyisoprene having a mixed 1,4-cis/3,4 structure: further characteristics of the process and of the polyisoprene obtained are reported in Table 2.
  • FIG. 29 shows the FT-IR spectrum of the polyisoprene obtained.

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