WO2005047350A2 - Heterogenisation of polymerisation catalysts by ionic liquids - Google Patents

Heterogenisation of polymerisation catalysts by ionic liquids Download PDF

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WO2005047350A2
WO2005047350A2 PCT/EP2004/052820 EP2004052820W WO2005047350A2 WO 2005047350 A2 WO2005047350 A2 WO 2005047350A2 EP 2004052820 W EP2004052820 W EP 2004052820W WO 2005047350 A2 WO2005047350 A2 WO 2005047350A2
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ionic liquid
solvent
hybrid
precursor
catalyst system
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PCT/EP2004/052820
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WO2005047350A3 (en
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Olivier Lavastre
Fabien Bonnette
Abbas Razavi
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Total Petrochemicals Research Feluy
Centre National De La Recherche Scientifique
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Priority to JP2006538848A priority Critical patent/JP2007511629A/en
Priority to EP04804514A priority patent/EP1689791A2/en
Priority to US10/579,361 priority patent/US20070155621A1/en
Publication of WO2005047350A2 publication Critical patent/WO2005047350A2/en
Publication of WO2005047350A3 publication Critical patent/WO2005047350A3/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
    • B01J31/12—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides
    • B01J31/14—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides of aluminium or boron
    • B01J31/143—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides of aluminium or boron of aluminium
    • C—CHEMISTRY; METALLURGY
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    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—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
    • C08F4/60—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 together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/70—Iron group metals, platinum group metals or compounds thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
    • B01J31/0277—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides comprising ionic liquids, as components in catalyst systems or catalysts per se, the ionic liquid compounds being used in the molten state at the respective reaction temperature
    • B01J31/0278—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides comprising ionic liquids, as components in catalyst systems or catalysts per se, the ionic liquid compounds being used in the molten state at the respective reaction temperature containing nitrogen as cationic centre
    • B01J31/0281—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides comprising ionic liquids, as components in catalyst systems or catalysts per se, the ionic liquid compounds being used in the molten state at the respective reaction temperature containing nitrogen as cationic centre the nitrogen being a ring member
    • B01J31/0284—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides comprising ionic liquids, as components in catalyst systems or catalysts per se, the ionic liquid compounds being used in the molten state at the respective reaction temperature containing nitrogen as cationic centre the nitrogen being a ring member of an aromatic ring, e.g. pyridinium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/18—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms
    • B01J31/1805—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms the ligands containing nitrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/18—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms
    • B01J31/1805—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms the ligands containing nitrogen
    • B01J31/181—Cyclic ligands, including e.g. non-condensed polycyclic ligands, comprising at least one complexing nitrogen atom as ring member, e.g. pyridine
    • B01J31/1815—Cyclic ligands, including e.g. non-condensed polycyclic ligands, comprising at least one complexing nitrogen atom as ring member, e.g. pyridine with more than one complexing nitrogen atom, e.g. bipyridyl, 2-aminopyridine
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F110/02—Ethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
    • B01J2531/02—Compositional aspects of complexes used, e.g. polynuclearity
    • B01J2531/0238—Complexes comprising multidentate ligands, i.e. more than 2 ionic or coordinative bonds from the central metal to the ligand, the latter having at least two donor atoms, e.g. N, O, S, P
    • B01J2531/0241—Rigid ligands, e.g. extended sp2-carbon frameworks or geminal di- or trisubstitution
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
    • B01J2531/80—Complexes comprising metals of Group VIII as the central metal
    • B01J2531/82—Metals of the platinum group
    • B01J2531/824—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
    • B01J2531/80—Complexes comprising metals of Group VIII as the central metal
    • B01J2531/84—Metals of the iron group
    • B01J2531/842—Iron
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
    • B01J2531/80—Complexes comprising metals of Group VIII as the central metal
    • B01J2531/84—Metals of the iron group
    • B01J2531/847—Nickel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
    • B01J31/12—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides
    • B01J31/14—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides of aluminium or boron
    • B01J31/146—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides of aluminium or boron of boron

Definitions

  • the present invention relates to the use of ionic liquids to heterogenise catalyst components and to the use of these solid insoluble systems for the polymerisation of olefins.
  • the present invention discloses a method for preparing an heterogenised single site catalyst component for the polymerisation of alpha - olefins that comprises the steps of: a) providing a halogenated precursor component of formula (I) b) reacting the halogenated precursor with an ionic liquid precursor in a solvent or without solvent to prepare an ionic liquid; c) mixing in a solvent one equivalent of the ionic liquid obtained in step b) with a metallic complex of formula (II) L 2 MY (II) wherein L is a coordinating ligand for the metallic site, said coo rdination being achieved by phosphorus, nitrogen or oxygen atoms.
  • L is preferably phophine, imine, aryloxy, alkyloxy or a mixture thereof.
  • M is a metal selected from Ni or Pd or Fe and Y is a halogen or an alkyl having from 1 to 12 carbon atoms; d) evaporating the solvent; e) retrieving an hybrid catalyst component/ionic liquid system.
  • the halogenated precursor of formula (I) reacts with a n ionic liquid precursor, preferably with N -alkylimidazole or pyridine, in or without a solvent, said solvent if present being for example tetrahydrofuran (THF), CH 2CI2 or CH 3CN.
  • a solvent if present being for example tetrahydrofuran (THF), CH 2CI2 or CH 3CN.
  • the anion X " can be selected from Cl “ , Br “ , I “ , BF “ , PF 6 “ , AsF 6 “ , SbF ⁇ “ , NO2 “ and NO3 “ . It can also be selected from compounds of formula AIR Z A' Z wherein R can be selected from an alkyl having from 1 to 12 carbon atoms, substituted or unsubstituted, or from a cycloalkyl having 5 or 6 carbon atoms, substituted or unsubstituted, or from an heteroalkyl, substituted or unsubstituted, or from an heterocycloalkyl, substituted or unsubstituted, or from an aryl having 5 or 6 carbon atoms, substituted or unsubstituted, or from aiv heteroaryl, substituted or unsubstit uted, or from an alkoxy, an aryloxy, an acyl, a silyl, a boryl, a phos
  • the cationic part of the ionic liquid may be prepared by protonation or alkylation o f a compound selected from imidazolium, pyrazoline, thiazole, triazole, pyrrole, indone, tetrazole, pyridine, pyrimidine, pyrazine, pyridazine, piperazine or piperidine.
  • the anion X " is Br " or BF 4 "
  • the cationic part is derived from imidazolium or pyridinium.
  • the preferred ionic liquid precursors are thus N - alkyl imidazole or pyridine. If the ionic liquid precursor is N -alkyl-imidazolium, the reaction is carried out at a temperature of from 50 to 1 50 °C, preferably of from 80 to 120 °C and for a period of time of from 1 to 24 hours, preferably of from 2 to 6 hours.
  • the resulting intermediate product is an ion pair of formula III x R -N ⁇ N
  • the reaction is carried out at a temperature of from 50 to 120 °C, preferably of from 90 to 110 °C and for a period of time of from 1 to 24 hours, preferably of about 3 hours.
  • Th e resulting product is an ion pair of formula IV
  • the intermediate product III or IV are mixed in stoechiometric proportions with the metallic complex of formula L 2MY2 in a solvent selected typically from CH 2CI2, THF, or CH 3 CN, at room temperature (about 25 °C), for a period of time of from 1 to 24 hours, preferably of from 1 to 2 hours.
  • the intermediate product (III) or (IV) can be reacted with a salt C + A " , wherein C + is a cation that can be selected from K + , Na + , NH 4 + , and A " is an anion that can be selected from PF 6 " , SbF 6 " , BF 4 " , (CF 3 -SO 2 )2N “ J CIO 4 ⁇ CF 3 SO 3 ⁇ NO 3 " or CF3CO2 " .
  • the reaction is carried out in a solvent selected typically from CH 2 CI 2 , THF or CH 3 CN at a temperature of from 50 to 80 °C , preferably of about 60 °C and for a period of time of from 6 to 48 hours, preferably of from 16 to 24 hours.
  • a solvent selected typically from CH 2 CI 2 , THF or CH 3 CN at a temperature of from 50 to 80 °C , preferably of about 60 °C and for a period of time of from 6 to 48 hours, preferably of from 16 to 24 hours.
  • the mixing with the ligand is then carried out as previously leading to an ion pair representing a supported catalytic component of formula VII if the ionic liquid is N-alkyl-imidazolium
  • the present invention also discloses an hybrid organometallic complex/ionic liquid catalyst system, obtainable by the method described here -above.
  • An active catalyst system is then obtained by addition of an activating agent.
  • the activating agent can be selected from alumoxanes or aluminium alkyls or boron-based activating agents depending upon the nature of Y.
  • the aluminium alkyls are of the formula AIR x and can be used wherein each R is the same or different and is selected from halides or from alkoxy or alkyl groups having from 1 to 12 carbon atoms and x is from 1 to 3.
  • Especially suitable aluminiumalkyl are dialkylaluminum chloride , the most preferred being diethylaluminum chloride (Et 2 AICI).
  • the preferred alumoxanes comprise oligomeric linear and/or cyclic alkyl alumoxanes represented by the formula : R-(AI-O) n -AIR2 for oligomeric, linear alumoxanes I R and
  • n is 1 -40, preferably 10-20, m is 3-40, preferably 3-20 and R is a C -i-C ⁇ alkyl group and preferably methyl.
  • Methylalumoxane (MAO) is preferably used.
  • Suitable boron -based activating agents may comprise triphenylcarbenium boronate such as tetrakis-pentafluorophenyl-borato-triphenylcarbenium [C (Ph) 3 + B( C ⁇ F ⁇ l as described in EP-A-0,427,696
  • the amount of activating agent is such that the Al M ratio is of from 100 to 1000.
  • an apolar solvent is added to the hybrid system resulting in quantitative precipitation in powder form.
  • the solvent phase is colourless and no longer contains any soluble catalyst.
  • the solvent is selected to generate a powder that dispers es easily therein. The powder is then injected into the reactor as dispersion.
  • the present invention further provides a method for homopolymerising or for copolymerising alpha -olefins that comprises the steps of: a) injecting into the reactor an apolar solve nt, then the heterogenised catalytic component and an activating agent; b) injecting the monomer and optional comonomer into the reactor; c) maintaining under polymerisation conditions; d) retrieving the polymer under the form of chips or blocks.
  • the conditions of temperature and pressure for the polymerisation process are not particularly limited.
  • the pressure in the reactor can vary from 0.5 to 50 bars, preferably from 1 to 20 bars and most preferably from 4 to 10 bars.
  • the polymerisation temperature can range from 10 to 100 °C, preferably from 20 to 50 °C and most preferably at room temperature (about 25 °C).
  • the solvent is apolar and is typically selected from an alkane, preferably n - heptane.
  • the reaction is carried out for a period of time of from 30 minute s to 24 hours.
  • the monomer that can be used in the present invention are alpha -olefins having from 3 to 8 carbon atoms and ethylene, preferably it is ethylene and propylene.
  • the polymerisation in the presence of ionic liquids produces polyethylene with unmodified structure (same fusion temperature, same molecular weight, same polydispersity index) but with a different macroscopic aspect.
  • the polymer particles have a larger size than that of particles obtained with nickel based catalyst system used without ionic liquids (see Table I).
  • the polymer particles have a diameter of at least 0.5 mm. They are thus less dangerous and easier to handle than powders (see Table II).
  • the fusion temperature of the polyethylene is comparable to that of polyethylene prepared with conventional catalyst systems.
  • the nature of the ionic liquid plays a significant role in the morphology of the resulting polymer as can be seen in Table II showing that the particle sizes of polymers prepared with ionic li quid based respectively on imidazolium or pyridinium are very different.
  • the catalytic systems based on ionic liquids of pyridinium type produce polymers having particle sizes of at least 2 mm whereas catalytic systems based on ionic liquid of imidazolium type produce polymers having particle sizes of about 0.5 mm.
  • the NMR spectra were as follows: 1 H NMR (300 MHz, CDCI 3 ) ⁇ : 10.23 ( s, 1), 7.63 ( tr, 1), 7.47 ( tr, 1), 4.27 ( tr, 2), 1.86 ( q, 2), 1.29 ( m, 4), 0.82 ( tr, 3).
  • the NMR spectra were as follows: 1 H NMR (300 MHz, CDCI 3 ) ⁇ : 9.58 ( d, 2), 8.52 ( tr, 1), 8.11 ( tr, 2), 4.93 ( tr, 2), 1.98 ( q, 2), 1.28 ( m, 4), 0.77 ( tr, 3).
  • the catalyst component was dissolved in CH 2 CI 2 and the ionic liquid dissolved in the same solvent was then added. The reaction medium was stirred during one hour at room temperature and the solvent was then evaporated under reduced pressure.
  • the quantities were respectively as follows: - compound V N ⁇ 5 micromoles (2.7 mg) of Ni-based catalyst, 5 micromoles (1.17 mg) of 1 -methyl-3-pentylimidazolium in 4 mL of CH 2 CI 2 - - compound V Fe : 1.2 micromoles (0.73 mg) of Fe -based catalyst, 1.2 micromoles (0.28 mg) of 1 -methyI-3-pentylimidazolium in 1 mL of CH 2 CI 2 .
  • - compound VI Fe 1.2 micromoles (0.73 mg) of Fe -based catalyst, 1.2 micromoles (0.276 mg) of N -pentylpyridinium in 1 mL of CH 2 CI 2 .
  • ionic liquid was 1 -methyl-3-pentylimidazolium bromide.
  • ionic liquid was 1 -methyl-3-pentylirnidazilium bromide c : ionic liquid was N-pentylpyridinium bromide.

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Abstract

The present invention discloses a method for preparing a dissolved catalyst component comprising the steps of: a) providing a halogenated precursor component of formula (I) X¯[CH2-]- b) reacting the halogenated bisimine precursor with an ionic liquid precursor in a solvent to prepare an ionic liquid; c) mixing in a solvent one equivalent of the ionic liquid prepared in step b) with a metallic complex of formula (II) L2MY2 wherein L is a coordinating ligand for the metallic site, said coordination being achieved by phosphorus, nitrogen or oxygen; d) evaporating the solvent; and e) retrieving a hybrid single site catalyst component/ionic liquid system. It also discloses an active catalyst system heterogenised by an ionic liquid and its use in the polymerisation of olefins.

Description

HETEROGENISATION OF POLYMERISATION CATALYSTS BY IONIC LIQUIDS.
The present invention relates to the use of ionic liquids to heterogenise catalyst components and to the use of these solid insoluble systems for the polymerisation of olefins.
Ionic liquids have been described in literature such as for example in US -A-
5,994,602, or in WO96/18459 or in WO01/81353. They disclose various methods for preparing ionic liquids and various applications.
These applications comprise oligomarisation of eth ene, propene or butene with various nickel-based precursors dissolved in ionic liquids as disclosed for example in Dupont et al. (Dupont, J., de Souza R.F., Suarez P.A.Z., in Chem.
Rev., 102, 3667, 2002.). The same document also discloses that Ziegler -Natta type polymerisation can be carried out in dialkylimidazolium halides/ammonium bgϋde ionic liquids using AICl3-χRxas cocatalysts.
Other applications include the use of ionic liquids that are liquid at or below room temperature as solvents for transiti on-metal-mediated catalysis, such as described for example in Welton (Welton T., in Chem. Rev., 99, 2071, 1999.).
Most attempts have proven successful in dimerisation or oligomerisation, but polymerisation remains problematic, especially with single site c atalyst components.
In many polymerisation methods such as for example in slurry processes, it is important to support the catalyst component. There is thus a need to develop new supports for single site catalyst systems that are active in the polymerisa tion of alpha-oleflns, and new methods for preparing these new supported catalyst systems.
It is an aim of the present invention to provide a method for preparing a single site catalyst component heterogenised by ionic liquids.
It is another aim of the p resent invention to provide an heterogenised single site catalyst component.
It is a further aim of the present invention to provide a process for polymerising alpha-oleflns using such heterogenised single site catalyst component.
It is also an aim of th e present invention to prepare new polymers with said new catalyst system.
Accordingly, the present invention discloses a method for preparing an heterogenised single site catalyst component for the polymerisation of alpha - olefins that comprises the steps of: a) providing a halogenated precursor component of formula (I)
Figure imgf000003_0001
b) reacting the halogenated precursor with an ionic liquid precursor in a solvent or without solvent to prepare an ionic liquid; c) mixing in a solvent one equivalent of the ionic liquid obtained in step b) with a metallic complex of formula (II) L2MY (II) wherein L is a coordinating ligand for the metallic site, said coo rdination being achieved by phosphorus, nitrogen or oxygen atoms. L is preferably phophine, imine, aryloxy, alkyloxy or a mixture thereof. M is a metal selected from Ni or Pd or Fe and Y is a halogen or an alkyl having from 1 to 12 carbon atoms; d) evaporating the solvent; e) retrieving an hybrid catalyst component/ionic liquid system.
All reactions are carried under argon at atmospheric pressure, using the standard Schlenk or glovebox techniques.
The halogenated precursor of formula (I) reacts with a n ionic liquid precursor, preferably with N -alkylimidazole or pyridine, in or without a solvent, said solvent if present being for example tetrahydrofuran (THF), CH 2CI2 or CH 3CN.
In the ionic liquid, the anion X" can be selected from Cl", Br", I", BF ", PF6 ", AsF6 ", SbFβ", NO2" and NO3". It can also be selected from compounds of formula AIR ZA'Z wherein R can be selected from an alkyl having from 1 to 12 carbon atoms, substituted or unsubstituted, or from a cycloalkyl having 5 or 6 carbon atoms, substituted or unsubstituted, or from an heteroalkyl, substituted or unsubstituted, or from an heterocycloalkyl, substituted or unsubstituted, or from an aryl having 5 or 6 carbon atoms, substituted or unsubstituted, or from aiv heteroaryl, substituted or unsubstit uted, or from an alkoxy, an aryloxy, an acyl, a silyl, a boryl, a phosphino, an amino, a thio or a seleno, wherein A" is a halogen and wherein z is an integer from 0 to 4. The cationic part of the ionic liquid may be prepared by protonation or alkylation o f a compound selected from imidazolium, pyrazoline, thiazole, triazole, pyrrole, indone, tetrazole, pyridine, pyrimidine, pyrazine, pyridazine, piperazine or piperidine.
Preferably, the anion X" is Br" or BF4 ", and preferably the cationic part is derived from imidazolium or pyridinium. The preferred ionic liquid precursors are thus N - alkyl imidazole or pyridine. If the ionic liquid precursor is N -alkyl-imidazolium, the reaction is carried out at a temperature of from 50 to 1 50 °C, preferably of from 80 to 120 °C and for a period of time of from 1 to 24 hours, preferably of from 2 to 6 hours. The resulting intermediate product is an ion pair of formula III x R-N^N
(III)
If the ionic liquid precursor is pyridinium, the reaction is carried out at a temperature of from 50 to 120 °C, preferably of from 90 to 110 °C and for a period of time of from 1 to 24 hours, preferably of about 3 hours. Th e resulting product is an ion pair of formula IV
x fV cH,
(IV)
The intermediate product III or IV are mixed in stoechiometric proportions with the metallic complex of formula L 2MY2 in a solvent selected typically from CH 2CI2, THF, or CH3CN, at room temperature (about 25 °C), for a period of time of from 1 to 24 hours, preferably of from 1 to 2 hours. The resulting product is a component of formula V if the ionic liquid precursor is a N -alkyl-imidazolium - ^N \=J L 2MY2 (V)
or of formula VI if the ionic liquid is pyridinium
Figure imgf000006_0001
(vi) wherein M, Ar and Y are as defined here -above.
Optionally, before the dissolution of the complex is carried out, the intermediate product (III) or (IV) can be reacted with a salt C +A", wherein C+ is a cation that can be selected from K+, Na+, NH4 +, and A" is an anion that can be selected from PF6 ", SbF6 ", BF4 ", (CF3-SO2)2N" J CIO4\ CF3SO3\ NO3 " or CF3CO2". The reaction is carried out in a solvent selected typically from CH 2CI2, THF or CH3CN at a temperature of from 50 to 80 °C , preferably of about 60 °C and for a period of time of from 6 to 48 hours, preferably of from 16 to 24 hours. The mixing with the ligand is then carried out as previously leading to an ion pair representing a supported catalytic component of formula VII if the ionic liquid is N-alkyl-imidazolium
Figure imgf000007_0001
(VII)
or of formula VIII if the ionic liquid is pyridinium
Figure imgf000007_0002
(VIII)
The present invention also discloses an hybrid organometallic complex/ionic liquid catalyst system, obtainable by the method described here -above.
An active catalyst system is then obtained by addition of an activating agent.
The activating agent can be selected from alumoxanes or aluminium alkyls or boron-based activating agents depending upon the nature of Y. The aluminium alkyls are of the formula AIR x and can be used wherein each R is the same or different and is selected from halides or from alkoxy or alkyl groups having from 1 to 12 carbon atoms and x is from 1 to 3. Especially suitable aluminiumalkyl are dialkylaluminum chloride , the most preferred being diethylaluminum chloride (Et2AICI).
The preferred alumoxanes comprise oligomeric linear and/or cyclic alkyl alumoxanes represented by the formula : R-(AI-O)n-AIR2 for oligomeric, linear alumoxanes I R and
(-AI-O-)m for oligomeric, cyclic alumoxanes, I R
wherein n is 1 -40, preferably 10-20, m is 3-40, preferably 3-20 and R is a C -i-Cβ alkyl group and preferably methyl. Methylalumoxane (MAO) is preferably used.
Suitable boron -based activating agents may comprise triphenylcarbenium boronate such as tetrakis-pentafluorophenyl-borato-triphenylcarbenium [C (Ph)3 + B( CβFδ l as described in EP-A-0,427,696
Other suitable boron -containing activating agents are described in EP -A-0,277,004.
The amount of activating agent is such that the Al M ratio is of from 100 to 1000.
After activation and eliminatio n of the solvent, an apolar solvent is added to the hybrid system resulting in quantitative precipitation in powder form. The solvent phase is colourless and no longer contains any soluble catalyst. The solvent is selected to generate a powder that dispers es easily therein. The powder is then injected into the reactor as dispersion.
The present invention further provides a method for homopolymerising or for copolymerising alpha -olefins that comprises the steps of: a) injecting into the reactor an apolar solve nt, then the heterogenised catalytic component and an activating agent; b) injecting the monomer and optional comonomer into the reactor; c) maintaining under polymerisation conditions; d) retrieving the polymer under the form of chips or blocks.
The conditions of temperature and pressure for the polymerisation process are not particularly limited.
The pressure in the reactor can vary from 0.5 to 50 bars, preferably from 1 to 20 bars and most preferably from 4 to 10 bars.
The polymerisation temperature can range from 10 to 100 °C, preferably from 20 to 50 °C and most preferably at room temperature (about 25 °C).
The solvent is apolar and is typically selected from an alkane, preferably n - heptane.
The reaction is carried out for a period of time of from 30 minute s to 24 hours.
The monomer that can be used in the present invention are alpha -olefins having from 3 to 8 carbon atoms and ethylene, preferably it is ethylene and propylene.
Examples. All reactions were carried out on a vacuum line under argon using sta ndard glovebox and Schlenk techniques.
During activation, the use of ionic liquids results in the formation of a precipitate that can be easily injected into the reactor.
The polymerisation, in the presence of ionic liquids produces polyethylene with unmodified structure (same fusion temperature, same molecular weight, same polydispersity index) but with a different macroscopic aspect. The polymer particles have a larger size than that of particles obtained with nickel based catalyst system used without ionic liquids (see Table I).
The polymer particles have a diameter of at least 0.5 mm. They are thus less dangerous and easier to handle than powders (see Table II).
It is also observed that the fusion temperature of the polyethylene is comparable to that of polyethylene prepared with conventional catalyst systems.
The nature of the ionic liquid plays a significant role in the morphology of the resulting polymer as can be seen in Table II showing that the particle sizes of polymers prepared with ionic li quid based respectively on imidazolium or pyridinium are very different. The catalytic systems based on ionic liquids of pyridinium type produce polymers having particle sizes of at least 2 mm whereas catalytic systems based on ionic liquid of imidazolium type produce polymers having particle sizes of about 0.5 mm.
Synthesis of catalyst components heterogenised by different ionic liquids-
Synthesis of 1 -methyl-3-pentylimdazolium bromide (III). Br
Figure imgf000011_0001
9.96 mL of N-methylimidazole (125 mmole) were introduced in a Schlenk followed by 22.16 mL of bromopentane (187.5 mmoles). The reaction medium was stirred during 2 hours at a temperature of 90 °C. After cooling down to room temperature, 40 mL of diethylic ether were added, to form a white precipitate. After filtra tion, the precipitate was washed 4 times with 40 mL of diethylic ether. After filtration, 24.7 g of a white solid were obtained with a yield of 85 %.
The NMR spectra were as follows: 1H NMR (300 MHz, CDCI3) δ: 10.23 ( s, 1), 7.63 ( tr, 1), 7.47 ( tr, 1), 4.27 ( tr, 2), 1.86 ( q, 2), 1.29 ( m, 4), 0.82 ( tr, 3).
13C NMR (75 MHz, CDCI3) δ: 137.17, 123.77, 122.09, 50.01 , 36.67, 29.92, 28.17, 21.98, 13.76.
Synthesis of N-pentyl pyridinium bromide (IV):
Br
Figure imgf000011_0002
0.4 mL of pyridine (5 mmoles) were introduced in a Schlenk followed by 0.8 mL of bromopentane (7.5 mmoles). The reaction medium was stirred during 2 hours at a temperature of 100 °C until formation of a precipitate. After cooling down to room temperature, the precipitate was washed 3 times with 5 mL of diethylic ether. After filtration and drying under reduced pressure, 1.09 g of a cream -coloured solid were obtained with a yield of 95 %.
The NMR spectra were as follows: 1H NMR (300 MHz, CDCI3) δ: 9.58 ( d, 2), 8.52 ( tr, 1), 8.11 ( tr, 2), 4.93 ( tr, 2), 1.98 ( q, 2), 1.28 ( m, 4), 0.77 ( tr, 3).
13, C NMR (75 MHz, CDCI3) δ: 145.18, 128.47, 61.80, 31.66, 27.92, 22.02, 13.75.
Synthesis of the nickel -based catalyst component.
Figure imgf000012_0001
9.96 mg (0.028 m moles) of bisimine were introduced in a Schlenk under inert atmosphere, followed by 5 mL of dichloromethane. 6.78 mg (0.02 mmoles) of (DME)NiBr2 were then added and the system was stirred during 16 hours at room temperature (about 25 °C). The solvent was e vaporated and the residue was washed twice with 3 mL of diethylic ether. After filtration and drying, 7 mg of brown powder were obtained with a yield of 63 %.
Synthesis of Fe -based catalyst component.
Figure imgf000012_0002
45.77 mg (0.23 mmoles) of tetrahydratedFe(ll) chlo ride were dried under reduced pressure at a temperature of 120 °C during 5 hours. The Fe(ll) chloride was added to bisimine in THF. The reaction medium remained under agitation at reflux during 30 minutes, it was then cooled down to room temperature. The i ron complex appeared as a precipitate. The mixture was filtered, dried under reduced pressure to preoduce 0.104 g of a blue complex with a yield of 87 %.
Synthesis of compounds V and VI .
The catalyst component was dissolved in CH 2CI2 and the ionic liquid dissolved in the same solvent was then added. The reaction medium was stirred during one hour at room temperature and the solvent was then evaporated under reduced pressure. The quantities were respectively as follows: - compound VNμ 5 micromoles (2.7 mg) of Ni-based catalyst, 5 micromoles (1.17 mg) of 1 -methyl-3-pentylimidazolium in 4 mL of CH 2CI2- - compound VFe: 1.2 micromoles (0.73 mg) of Fe -based catalyst, 1.2 micromoles (0.28 mg) of 1 -methyI-3-pentylimidazolium in 1 mL of CH 2CI2. - compound VI Fe: 1.2 micromoles (0.73 mg) of Fe -based catalyst, 1.2 micromoles (0.276 mg) of N -pentylpyridinium in 1 mL of CH 2CI2.
Polymerisation of ethylene.
Polymerisation of ethylene in the Ni -based catalyst system.
The polymerisation conditions were as follows: - 5 micromoles of catalyst component, 5 micromoles of ionic liquid and 60 mL of n-heptane; - addition of 300 mole -equivalents of MAO with respect to the catalyst component; - T = 25 °C; - P = 4 bars; - t = 2 hours ; - the polymer was treated with acid methanol (10 vol% of HCI) TABLE I.
Figure imgf000014_0001
: measured after one hour b. ionic liquid was 1 -methyl-3-pentylimidazolium bromide.
Polymerisationof ethylene with Fe -based catalyst system.
The polymerisation with the Fe -based catalyst system were as follows: - 1.2 micromoles of catalyst component, 1.2 micromoles of ionic liquid and 60 mL of n -heptane; - addition of 1000 mole -equivalents of MAO with respect to the catalyst component; :-, T = 25 °C; - P = 4 bars; - t = 1 hour ; - the polymer was treated with acid methanol (10 vol% of HCI).
TABLE II.
Figure imgf000014_0002
a : measured after one hour b: ionic liquid was 1 -methyl-3-pentylirnidazilium bromide c: ionic liquid was N-pentylpyridinium bromide.

Claims

CLAIMS.
1. A method for preparing a dissolved catalyst component comprising the steps of: a) providing a halogenated precursor component of formula (I)
-X-[-CH2-]- (I) b) reacting the halogenated precursor with an ionic liquid precursor in a solvent to prepare an ionic liquid; c) mixing in a solvent one equivalent of the ionic liquid prepared in step b) with a metallic complex of formula (II) L2MY2 (II) wherein L is a coordinating ligand for the metallic site, said coordination being achieved by phosphorus, nitrogen or oxygen; d) evaporating the solvent; and e) retrieving a hybrid single site catalyst component/ionic liquid system.
2. The method of claim 1 wherein the ionic liquid precursor is N -alkyl- imidazolium or pyridinium.
3. The method of claim 1 or claim 2 wherein between step b) and step c), the reaction product of step b) is reacted with an ionic compound C +A", wherein C+ is a cation selected from K \ Na+, NH +, and A" is an anion selected from PF6 ", SbF6 ", BF4 ", (CFg-SOz^ ", CIO4", CF3SO3", NO3 " or CF3CO2 ".
4. The method of any one of the preceding cla ims wherein the solvent used in steps b) and step c) is selected from THF, CH CI2 or CH3CN.
5. A hybrid organometallic complex/ionic liquid system obtainable by the method of any one of claims 1 to 4.
6. A hybrid catalyst system comprising the hybrid organomet allic complex/ionic liquid system of claim 5 and an activating agent.
7. The hybrid catalyst system of claim 6 wherein the activating agent is methylaluminoxane and wherein Y is a halogen.
8. The hybrid catalyst system of claim 7 wherein the amount of methylaluminoxane is such that the Al/M ratio is of from 100 to 1000.
9. A method for homopolymerising or copolymerising alpha -olefins that comprises the steps of: a) heterogenising the hybrid catalyst system of any one of claims 6 to 8 by addition of an apolar solvent ; b) injecting into the reactor an apolar solvent and the heterogenised catalyst system of step a) c) injecting the monomer and optional comonomer into the reactor; / ; d) maintaining under polymerisation conditions; e) retrieving the polymer under the form of chips or bl ocks.
10. The method of claim 9 wherein the apolar solvent is n -heptane.
11. The method of claim 9 or claim 10 wherein the monomer is ethylene or propylene.
12. A polymer having particle sizes of at least 0.5 mm obtainable by the process of any one of claims 9 to 1 1.
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