REVIEWS
The Search for New-Generation Olefin Polymerization Catalysts: Life beyond Metallocenes
George J. P. Britovsek, Vernon C. Gibson,* and Duncan F. Wass
The introduction of well-defined, sin- generally acknowledged that no single record of being applied in this way, has gle-site organotransition metal olefin class of catalyst will be capable of signposted the way for further techno- polymerization catalysts in the early controlling all of the macromolecular logically significant advances in the 1980s highlighted the possibilities for parameters relevant to a wide and field. In this review, we highlight the controlling and dramatically improving varied range of polyolefinic products. key advances that have occurred in the the properties of commodity polymer Over the past few years, an intense discovery and development of non- products such as polyethylene and search has therefore developed, in Group 4 metallocene catalysts, amply polypropylene. Group 4 metallocenes both academic and industrial research demonstrating that there are signifi- and half-sandwich titanium ± amide laboratories, for new-generation cata- cant signs of life beyond the Group 4 complexes (constrained-geometry cat- lysts. Some of the most significant metallocenes. alysts) have been at the forefront of recent developments have occurred these developments, and, as we ap- with late transition metal systems. Keywords: homogeneous catalysis ´ proach the late 1990s, these catalysts Particularly, the discovery of excep- olefins ´ polymerizations ´ transition are increasingly finding their way into tionally active catalysts based on iron, metals commercial operations. However, it is a metal that had no previous track
1. Introduction
1.1. Background X X M M X Me Si X The past 15 years have witnessed tremendous advances in 2 N the design and application of organometallic complexes as a- tBu olefin polymerization catalysts; many are now reaching the early stages of commercialization. These developments have A B grown out of an increased understanding of the factors that Scheme 1. Group 4 metallocenes (A) and constrained-geometry catalysts are important for stabilizing polymerization-active metal (B). centers and controlling their activity and selectivity, combined with the industrially important discovery that methylalumox- ane (MAO) cocatalysts afford highly active and long-lived greater control over the properties of the resultant polymers catalyst systems. To date, Group 4 metallocenes (A, and to extend the family of products to new monomer Scheme 1) and related catalyst systems such as the half- combinations, the search is gathering apace for yet new highly sandwich amide or constrained-geometry catalysts (B) have active, selective catalyst families that tolerate a variety of been at the forefront of these developments. functional groups. In this review we shall highlight recent However, the search for new catalysts would appear to be advances in the search for new catalysts, focusing primarily on far from over. Driven by industrys desire to obtain ever ligand ± metal complex design and catalyst activity rather than the properties of the resultant polymeric materials. A simple [*] Prof. Dr. V. C. Gibson, Dr. G. J. P. Britovsek, D. F. Wass classification scheme is outlined that allows ligand ± metal Department of Chemistry combinations for active catalysts to be charted. Variations on Imperial College of Science, Technology and Medicine Group 4 metallocene catalyst systems will not be discussed in Exhibition Road, South Kensington, London SW7 2AY (UK) Fax: (44)171-5945810 any detail here since they have been reviewed extensively E-mail: [email protected] elsewhere.[1±7]
Angew. Chem. Int. Ed. 1999, 38, 428 ± 447 WILEY-VCH Verlag GmbH, D-69451 Weinheim, 1999 1433-7851/99/3804-0429 $ 17.50+.50/0 429 REVIEWS V. C. Gibson et al.
[8] 1.2. The Active Site Na[B{3,5-(CF3)2C6H3}4] or silver salts such as AgBF4 or
AgOSO2CF3 (AgOTf) for the later transition metals. It is generally agreed that the catalytically active species in Route B involves the abstraction of an alkyl ligand or, more olefin polymerization is a coordinatively unsaturated cationic strictly, an alkyl anion. Reagents used for these ligands are, alkyl complex [LnMR] that is stabilized by several ligands L for example, [Ph3C][B(C6F5)4], [PhNHMe2][B(C6F5)4], [8] (Scheme 2). To generate such species several methods can be [H(OEt2)2][B{3,5-(CF3)2C6H3}4] or B(C6F5)3. Whereas the employed; three different routes (A, B, and C) are shown in trityl reagent is an abstracting agent, the anilinium salt and the Scheme 2. acid remove the alkyl ligand by protonation. In the case of
B(C6F5)3 the alkyl ligand is only partly abstracted leading to ªcation-likeº catalytic species.[9, 10] The applications of per- fluorophenyl-substituted boranes and borates as cocatalysts R R have been recently reviewed.[11] LnM L M n Route C is a combined alkylation and abstraction process, X R which can be achieved by treating a dihalide procatalyst A B + first with an alkylating species and then with one of the R aforementioned alkyl-abstracting agents, for example a tri- L M n alkylaluminum compound followed by B(C6F5)3 . Some re- agents can perform both processes, for example, alkylalumi- num halides and especially alumoxanes such as methylalumi- C noxane (MAO). Albeit the structure of MAO is still largely X unknown, the high activities and long catalyst lifetimes it affords are well documented and still the subject of ongoing LnM study.[12±15] X Scheme 2. Three different routes to the catalytically active species Besides these classical activation methods, an alternative strategy for the generation of a catalytic active species has [LnMR] (see text for details). & represents the site of coordinative unsaturation. [16] been introduced by Erker et al. Treatment of a [Cp2Zr(bu-
tadiene)] complex (C) with B(C6F5)3 results in a metallocene- borate-betaine system (D), which is highly active in olefin Route A involves the abstraction of an anionic ligand (e.g. polymerization (Scheme 3).[17, 18] In these systems the cationic a halide) and its substitution for a ªnoncoordinatingº and anionic parts are combined within the same molecules, anion by a salt elimination. Common reagents are ªzwitterionic metallocenesº.[19]
Vernon C. Gibson, born in 1958 in Grantham, England, studied chem- istry at the University of Sheffield before moving to the University of Oxford, where he was awarded a D. Phil. in 1983 for work on the coordination and organometallic chemistry of the early transition metals carried out in the group of M. L. H. Green. He then spent two years as a NATO postdoctoral researcher at the California Insti- V. C. Gibson G. J. P. Britovsek D. F. Wass tute of Technology with J. E. Ber- caw before returning to England to take up a lectureship in chemistry at Durham University in 1986. He was appointed to a Chair of Chemistry at Durham sponsored by BP Chemicals in 1993. In 1995 he and his group moved to Imperial College, London, where he is Head of the Centre for Catalysis and Advanced Materials.
George J. P. Britovsek, born in 1966 in Heerlen, The Netherlands, studied chemistry at the Technische Universität Aachen (Germany). In 1993 he earned his doctorate from this university under the direction of W. Keim. He then spent two years as a postdoctoral researcher at the University of Tasmania (Australia) with K. J. Cavell, before joining the group of V. C. Gibson at Imperial College in London in 1996.
Duncan F. Wass was born in Leicester, England, in 1973. After studying chemistry at Durham University, he moved to Imperial College in 1995 where he is working for his Ph.D. under the supervision of V. C. Gibson.
430 Angew. Chem. Int. Ed. 1999, 38, 428 ± 447 Olefin Polymerization Catalysts REVIEWS
Ar Cp2Zr ( ) C Ð B(C6F5)3 Ar N + Zr+ O N X X F F M N N M X X N M X D tBu N B F Ar N tBu X 3 Ar F F G [NÐ,NÐ] H trig-[NÐ,O,NÐ] I planar-[NÐ,N,NÐ] Scheme 4. Examples of zirconium(iv) procatalysts to illustrate the ligand classifications.
PPh Me Ti Zr 2 Me2Si N site of the trigonal bipyramid, while in the case of I the N,N,N R tridentate chelating ligand binds in a planar arrangement, E F thereby leaving the chloro ligands to occupy the equatorial Scheme 3. The zwitterionic approach to active polymerization catalysts. sites of the trigonal bipyramid. The ligands present in G, H, and I may be represented as [N ,N ], trig-[N ,O,N ], and Similarly Devore and co-workers independently demon- planar-[N ,N,N ], respectively. A description of this kind will strated the same principles for constrained-geometry titanium be found adjacent to the pictorial representations of the complexes E.[20] Piers and co-workers have shown recently procatalysts under discussion here, but will not be elaborated that simple alkenes, for example coordinated ethylene in upon. II [Cp2Zr (C2H4)(PPh2Me)] (F), also react with B(C6F5)3 to form a zwitterionic metallocene capable of initiating olefin polymerization.[21] 1.4. Catalyst Activities In this review, except for those cases where well-defined catalysts are reported, we have not considered in any detail The main focus of this review is catalyst performance for the method of activation employed. By far the most common ethylene polymerization, though reference to other a-olefins approach has been activation of a dialkyl or dihalide is included wherever they have been reported. A ªhealth precursor with MAO. In these cases the alkyl or halide group warningº has to be applied when comparing catalyst activities are referred to as a generic group X. reported by different groups of researchers, since experimen- tally determined values are highly dependent upon the precise reaction conditions, including stirring rate and the configu- ration of the reactor. Also, often little or no information is 1.3. Ligands given about the kinetic profile or lifetime of the catalyst, with the consequence that a short polymerization run The attendant ligands in polymerization-active metal com- with a catalyst that is active only for 30 seconds before dying plexes have four important roles: 1) control over the metal may give an ªinflatedº figure of merit compared to an coordination number, 2) control over the metal coordination activity reported for a one-hour run. Information about the geometry, 3) control over the formal oxidation state of the catalysts kinetic profile is very useful in allowing the metal, and 4) steric protection of the active site and influence most appropriate operating conditions to be chosen. For over (stereo)selectivity. To assist the reader in categorizing example, solution-phase catalysts generally require shorter polymerization-active metal ± ligand combinations and there- reactor residence times than for a supported gas-phase by illuminate possible ways forward for future catalyst design, catalyst. we have used a simple classification system that allows the To give the reader some feeling for how active a particular ligands to be categorized according to the number and nature catalyst is compared to other systems, we have converted the of the donor atoms and also the ligand charge, including an activity figures available in the literature to units of indication of which metal-attached ligand atoms bear the gmmol 1 h 1 bar 1 and placed the catalyst on a scale of merit formal charge. ranging from very low to very high, as shown in Table 1. By way of example, consider the series of active zirconium procatalysts G ± I (Scheme 4). The choice of chelating di- anonic diamide ligands allows zirconium(iv) dichloro frag- Table 1. Rating of the effectiveness of a catalyst based on its activity. ments to be stabilized either in a pseudo-tetrahedral environ- Rating Activity [gmmol 1 h 1 bar 1] ment for G or in distorted trigonal-bipyramidal environments very low < 1 for H and I. Moreover, the choice of an ether or pyridyl bridge low 1 ± 10 influences the relative dispositions of the metal-attached moderate 10 ± 100 atoms. In the case of H there is a trigonal arrangement of the high 100 ± 1000 very high > 1000 N,O,N atoms of the ligand with the oxygen occupying the axial
Angew. Chem. Int. Ed. 1999, 38, 428 ± 447 431 REVIEWS V. C. Gibson et al.
2. Catalysts with Group 3 and Rare Earth Metals Ligand design for organoyttrium olefin polymerization catalysts has also been following the trends of Group 4 catalysts (Scheme 6). Bis(cyclopentadienyl) complexes 6 2.1. Group 3 Metal Catalysts have been the first reported to show moderate activity as
Neutral Group 3 alkyl complexes of scandium and yttrium are isoelectronic with Group 4 cationic alkyl complexes; R R compare, for example, [Cp2ScR] and [Cp2ZrR] . This analogy has been used in the design of Group 3 olefin polymerization catalysts, as exemplified by the complexes shown in Y X Me2Si Y X Schemes 5 and 6. A potentially significant advantage of Group 3 catalysts is that they are single-component catalysts; no cocatalyst is R R needed. Commonly the neutral alkyl complexes, [{L MR} ], 2 2 R = H5, Me5, SiMe3 R = Me4, (SiMe3)2 are dimeric in the solid state and in solution, and react with H 2 6 [C Ð,C Ð] 7 [C Ð,C Ð] under mild conditions to yield the corresponding hydrides, 5 5 5 5
[{L2MH}2]. Monomeric complexes have been obtained Ph through the use of very bulky ligands or the addition of a SiMe3 donor ligand. The general low olefin polymerization activity OAr N R of scandium complexes such as 1 ± 3 (Scheme 5) has enabled Me Si N Y Y 3 Y X detailed mechanistic investigations of the polymerization H Me Si N ArO 3 process.[22±26] Mono(pentamethylcyclopentadienyl)alkoxy N scandium compounds have not shown any polymerization R = H, alkyl Ph SiMe3 Ar = C6H3tBu2 activity, probably due to the formation of an oxygen-bridged Ð Ð Ð Ð 8 [C5 ,O ] 9 [N2 ,N2 ] complex;[27] this is in contrast to observations made for Scheme 6. Yttrium complexes used as olefin polymerization catalysts. analogous yttrium complexes (see below).[28] An anionic scandium complex with a dianionic dicarbollide ligand was found to be remarkably unreactive towards ethylene,[29] ethylene polymerization catalysts (42 gmmol 1 h 1 bar 1).[33] similar to the analogous neutral Group 4 titanium complex.[30] ansa-Metallocene analogues 7 have been investigated by the Most of the ligand systems used in Group 3 catalysts have groups of both Bercaw and Yasuda, the latter has reported followed from ligands that have been shown to be successful high activities for the polymerization of ethylene for Group 4 systems, although the Group 3 metals are (584 gmmol 1 h 1 bar 1).[34±37] The reaction of hydridoyttrium generally much less well explored. Recently, scandium complexes bearing bulky aryloxide ligands with ethylene has procatalysts containing tridentate ligands have been de- been reported to lead to the rapid formation of polyethylene. scribed, one containing a monoanionic planar-[P,N ,P] No quantitative data has been given, but valuable mechanistic amide-diphosphane ligand (4), the other a neutral information has been obtained from the reaction of the trig-[N,N,N] triazacyclononane ligand (5). Both are capable bridged hydride initiator 8 with olefins.[28, 38, 39] Benzamidinate of polymerizing ethylene, though no activity figures were ligands (9) have been employed by Teuben and co-workers given.[31, 32] which have shown only very low ethylene polymerization activity.[40, 41] R R R
2.2. Rare Earth Metal Catalysts Sc X Me2Si Sc X Sc X Me Si 2 N Lanthanide- and actinide-based olefin polymerization cat- alysts (10, Scheme 7) have invariably been stabilized with tBu R R substituted cyclopentadienyl ligands. The first reports on the
R = Me5 R = Me4,tBu R = Me4 application of organometallic complexes of rare earth metals Ð Ð Ð Ð Ð Ð in ethylene polymerization appeared in 1978. Ballard and co- 1 [C5 ,C5 ] 2 [C5 ,C5 ] 3 [C5 ,N ] workers at ICI reported moderate catalytic activities at 1008C (82 gmmol 1 h 1 bar 1) using an alkyl metallocene complex of PiPr 2 N erbium,[33] and Marks et al. described bis(pentamethylcyclo- Si pentadienyl)uranium monochloride as a potent catalyst for X N N N Sc ethylene polymerization.[42] Mechanistic studies of the X Sc Si reversible insertion of propene into the Lu H bond of PiPr X X [{(C Me ) LuH} ] with subsequent competitive b-H and b- 2 X 5 5 2 2 Me elimination were reported a few years later by Watson and 4 planar-[P,NÐ,P] 5 trig-[N,N,N] co-workers at DuPont. They have also shown that Scheme 5. Scandium complexes used as olefin polymerization catalysts. alkyl metallocene complexes of lutetium are ethylene
432 Angew. Chem. Int. Ed. 1999, 38, 428 ± 447 Olefin Polymerization Catalysts REVIEWS
[51±54] R R B(C6F5)3 . Only moderate activities are obtained with these systems. For monocyclopentadienyl trialkyl complexes 12 (Scheme 8), where the catalyst [Cp*TiMe2] (Cp* C5Me5) M X Me2Si M X contains a ligand system that is a combination of a Cp ligand and an alkyl ligand [C ,C5 ], moderate activities have been
R R
R = Me5, SiMe3 R = Me4, (SiMe3)2 M = La, Nd, Sm, Er, Yb, Lu, U M = Nd, Sm, Lu R n N 10 [C Ð,C Ð] 11 [C Ð,C Ð] R 5 5 5 5 M Zr Scheme 7. Lanthanide and actinide metallocenes investigated as olefin ZrCl2 R R polymerization catalysts.
R = Me, CH2Ph 2 Rn = 1,3-(SiMe3)2
Ð Ð Ð Ð Ð Ð polymerization catalysts with moderate activity 12 [C5 ,C ] 13 [C5 ,C3 ] 14 [C3 ,N,C3 ,N] (66 gmmol 1 h 1 bar 1).[43±45] Studies by Schumann, Marks, Y and co-workers on hydride metallocene and ansa-metallocene B P complexes of lanthanum, neodymium, samarium, and luteti- R um (11) have shown remarkably high activities Cl Cl Zr Zr (146400 gmmol 1 h 1 bar 1 for lanthanum). However, these R Cl Cl figures are only initial activities, as polymerizations have been B Y P run only for a very short time (typically five seconds).[46±48] Ð Ð Ð Ð The corresponding alkyl metallocene complexes (X 15 [C5B ,C5B ] 16 [C4P ,C4P ] Scheme 8. Group 4 procatalysts with alkyl [C ], allyl [C ], and modified CH(SiMe3)2) of La, Nd, and Lu are reported to be inactive 3 Cp [C X ] ligands. towards ethylene at room temperature.[48] In contrast, alkyl n metallocene complexes (X CH(SiMe3)2) of samarium have shown moderate activities,[37, 49] and the Nd complex has been reported, both by Baird et al. (46 gmmol 1 h 1 bar 1)[55±57] and reported to be a ªgoodº catalyst at higher temperatures by Zambelli et al. (80 g mmol 1 h 1 bar 1).[52, 58] Ethylene poly- (1608C).[50] merization results obtained by Bochmann et al. have shown that the order of activity is [Cp2ZrR] > [CpZrR2] > [ZrR ] .[53] One Cp ± aryl combination, where aryl C F , 3. Group 4 Metal Catalysts 3 6 5 has been reported by Baird and co-workers to give moderate activity for ethylene polymerization (16 gmmol 1 h 1 bar 1).[57] In the search for new non-metallocene olefin polymer- ization catalysts, the vast majority of recent research effort has been directed towards the synthesis of alternative Group 4 3.1.1.2. Allyl Ligands [C3 ] catalysts. The wide variety of procatalysts that has been Compared to alkyl ligands (two-electron donor) and a investigated necessitates a more systematic treatment of the cyclopentadienyl ligand (six-electron donor) the intermediate differing ligand types. In Section 3.1 procatalysts of the type allyl ligands (four-electron donor) have received little atten- [LnMX2] which, when activated, give rise to cationic alkyl tion as spectator ligands in olefin polymerization catalysis. active sites [LnMR] are described. This section is further This may be due to the intrinsic higher reactivity of the allyl divided according to carbon-, nitrogen-, and oxygen-based ligand compared to the cyclopentadienyl ligand. One report ligand types. Section 3.2 outlines applications of dianionic has described the use of a [Cp(allyl)Zr(dienyl)] complex (13, ligands ((L2)2 ) to generate neutral 14-electron complexes Scheme 8) which can be activated with B(C6F5)3 (the method 1 2 1 [L L MR] (where L is typically a monoanionic Cp ligand) as described by Erker et al.[16]) to a zwitterionic diallyl zirconium the active centers. complex. Moderate polymerization activities are observed for this system (98 gmmol 1 h 1 bar 1), but the broad molecular weight distributions suggest the loss of active site uni- 3.1. Cationic Group 4 Metal Complexes formity.[59] Bergman and Lavoie have shown recently that allyl ligands with an additional donor [C3 ,N] are 3.1.1. Carbon-Based Ligands suitable ligand systems to generate zirconium complexes 14 with moderate ethylene polymerization activity 3.1.1.1. Alkyl Ligands [C ] (17 gmmol 1 h 1 bar 1).[60] Simple homoleptic s-hydrocarbyl complexes of Group 4 transition metals, for example [Ti(CH C H ) ] or 2 6 5 4 3.1.1.3. Cp Analogues [C5X ] and [C4X ] [Zr(CH2C6H5)4], have produced active ethylene polymeriza- tion catalysts when activated with suitable Lewis acids One modification of a Cp ligand is formally obtained by the such as MAO, [Me2NHPh][B(C6F5)4], [Ph3C][B(C6F5)4], or insertion of a BY unit into the Cp ring, resulting in a
Angew. Chem. Int. Ed. 1999, 38, 428 ± 447 433 REVIEWS V. C. Gibson et al.