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Ethylene Polymerization over Metal–Organic Framework Crystallites and the Influence of Linkers on Their Fracturing Process

  • Miguel Rivera-Torrente
    Miguel Rivera-Torrente
    Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
  • Paul D. Pletcher
    Paul D. Pletcher
    Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
  • Maarten K. Jongkind
    Maarten K. Jongkind
    Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
  • Nikolaos Nikolopoulos
    Nikolaos Nikolopoulos
    Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
  • , and 
  • Bert M. Weckhuysen*
    Bert M. Weckhuysen
    Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
    *E-mail for B.M.W.: [email protected]
Cite this: ACS Catal. 2019, 9, 4, 3059–3069
Publication Date (Web):March 11, 2019
https://doi.org/10.1021/acscatal.9b00150

Copyright © 2022 American Chemical Society. This publication is licensed under CC-BY-NC-ND.

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Supporting Info (1)»

Abstract

The physical properties and morphologies of polymers are pivotal for their manufacturing and processing at the industrial scale. Here, we present the formation of either fibers or micrometer-sized polyethylene beads by using the MIL-100(Cr) and MIL-101(Cr) zeotypes. The MOF structures have been used for ethylene polymerization with diethylaluminum chloride (DEA) as a cocatalyst, resulting in very different activities and morphologies. In situ DR UV–vis–NIR and CO-probe FT-IR spectroscopy revealed the formation of different types of Cr species for each catalyst material, suggesting that the linker (for the same metal and topological structure) plays a crucial role in the formation of Cr olefin polymerization sites. Activity in ethylene polymerization in toluene at 10 bar and 298 K was related to the observed spectra, corroborating the presence of different types of active sites, by their different activities for high-density polyethylene (HDPE) formation. SEM micrographs revealed that although MIL-100 and MIL-101 exhibit identical zeolitic MTN topology, only the latter is able to collapse upon addition of DEA and subsequent ethylene insertion and to fracture forming polymer beads, thus showing noticeable activity in HDPE formation. We ascribed this effect to the higher pore volume and, thus, fragility of MIL-101, which allowed for polymer formation within its larger cages. MOFs were compared to the nonporous chromium(III) benzoate [Cr3O(O2CPh)6(H2O)2](NO3nH2O complex (1), in order to study the effect of the embodiment in the porous framework. The properties of the polymer obtained under identical reaction conditions were comparable to that of MIL-101(Cr) but very different morphologies were observed, indicating that the MIL-101(Cr) structure is necessary to impart a certain architecture at the microscale. This work clearly shows that MOFs can be used as catalytically active morphology regulators for ethylene polymerization. Moreover, even for an identical topology and metal in a MOF structure, the linker and the pore structure play crucial roles and have to be carefully considered in the design microporous coordination polymers for catalytic purposes.

1. Introduction

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Polyethylene (PE) production has been estimated to reach 100 million tons per year by 2020 and will continue to be an ubiquitous material for our modern society in the decades to come. A wide variety of reactor configurations (i.e. liquid, slurry, and gas phase) and catalyst materials (metallocene, Ziegler–Natta, and Phillips) are used for its production depending on the required physicochemical properties, such as density, melting point, and viscosity as well as morphology, (1) that need to be conferred to the polymer for further processing. (2−4) In order to alter the architecture of the polymer at the macroscale, different systems in which the support plays the role of a “cast” have been used in the past. Examples of such efforts include the so-called extrusion polymerization in which the active olefin polymerization sites have been incorporated in the family of MCM-41 and SBA-15 mesoporous materials, yielding polyethylene microcrystalline fibers. (5−10)
Metal–organic frameworks (MOFs) are another interesting class of porous materials that have been recently used for polymer templating. (11−17) MOFs consist of coordination networks with organic ligands connected to metal nodes or cations, containing potential voids upon guest molecule removal. (18) Their well-defined metal sites, together with their porosity, have fostered their use as single-site porous catalysts. (19−21) Indeed, a number of MOFs have been studied as solid catalysts for the polymerization and oligomerization of short olefins, due to their industrial relevance and relatively mild conditions required for operation, together with the necessity of fine-tuning selectivity. (22−26) Ethylene oligomerization (in both the liquid (27) and the gas phase (28−33)) and polymerization, (34−37) as well as propylene dimerization in the gas phase, (38−40) or even isoprene polymerization, (41) can be catalyzed by a number of MOFs, postsynthetic modification being necessary in most cases. However, despite its paramount importance in later applications, polymer morphology has been often overlooked and most of the MOF-based catalyst materials described often show either poorly or nonshaped materials. Recently, Liu et al. (42) reported on the selective oligomerization of ethylene by the chromium nodes of MIL-100(Cr) after activation with organoaluminum species, wherein the activity and selectivity can be tuned by simple thermal treatments without the need for additional modifications on the MOF framework. Their work has inspired our efforts in investigating the possibilities of MIL-100(Cr) materials for olefin polymerization. MIL-100(Cr) (43) and MIL-101(Cr) (44) frameworks (where MIL stands for Matériau de l’Institut Lavoisier) are among the most studied MOFs due to their high porosity (SBET ≈ 1500–3000 m2/g), tunability, and chemical and hydrothermal stability.
In this work, we have taken advantage of the ability of MIL-101(Cr), in contrast to the more solid MIL-100(Cr) and the homogeneous Cr complex [Cr3O(O2CPh)6(H2O)3](NO3nH2O (1), to fracture upon addition of a strongly oxophilic organoaluminum activator and subsequent ethylene polymerization in the liquid phase. Moreover, we sought to understand the effects of the cocatalysts when they are used in combination with these MOF materials, as well as the reaction conditions, by means of in situ spectroscopy together with a detailed analysis of the polymer products formed. We will show that even for an identical pore structure and metal in a MOF, the organic linker plays a crucial role and has to be chosen specifically to obtain targeted polyolefin polymer products.

2. Experimental Section

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2.1. Catalyst Preparation

The synthesis of the coordination complex 1, MIL-100(Cr), and MIL-101(Cr) was carried out according to previously published procedures. (43−45) Details on the preparation and routine characterization of the materials can be found in the Supporting Information.

2.2. Material Characterization

X-ray diffraction (XRD) patterns were obtained with a Bruker-AXS D2 Phaser powder X-ray diffractometer in Bragg–Brentano geometry, using Co Kα1,2 = 1.79026 Å, operated at 30 kV. The measurements were carried out between 2 and 30° using a step size of 0.05° and a scan speed of 1 s, with a 0.1 mm slit for the source. Simulated XRD patterns were obtained by processing the corresponding .cif files with VESTA (λ = 1.79026 Å, fwhm = 0.2) from refs (43and46).
N2 adsorption isotherms were measured at 77 K on a Micromeritics TriStar 3000 instrument. Prior to all measurements, samples were dried at 423 K under dynamic vacuum. Specific surface areas (SSAs) were calculated using the multipoint BET method (0.05 < p/p0 < 0.25). Pore volumes (Vp) were calculated by the t-plot method; pore size distributions (PSDs) were obtained by DFT using N2 and spherical pores in the package MicroActive 4.06 (Micromeritics).
Fourier transform infrared (FT-IR) spectroscopy measurements at 85 K were recorded with a PerkinElmer 2000 instrument, in a specially designed cell fitted with CaF2 windows. The degassed (at 423 K) MOF materials studied were pressed into 3–5 mg wafers inside of a glovebox and fitted into the FTIR cell. The cell was sealed, connected to the gas/vacuum system, and carefully evacuated to ∼10–5 mbar at 298 K. A 10% CO/90% He (v/v) mixture was slowly introduced into the cell until the pressure reached 250 mbar and allowed to equilibrate. The sample was then cooled using liquid nitrogen (to 85 K) to allow the CO to saturate and equilibrate on the surface. The cell gas pressure was decreased, and spectral measurements were taken after the pressure stabilized. A final measurement was taken after outgassing the cell for 20 min. To measure the CO FT-IR spectra of the sample activated at 623 K, the cell was slowly warmed to 298 K under vacuum and then heated to 623 K at a rate of 5 K min–1 and maintained at 623 K for 1 h. The sample was then cooled to room temperature, and the previously described CO FT-IR measurement protocol was used to probe the surface acidity. For the Et2AlCl (DEA, Sigma-Aldrich, 97%) activated samples, ∼20 mg of MOF material was mixed with 100 equiv of DEA for 20 min in the glovebox. The solvent was decanted and the remaining solid dried under vacuum. Then, ∼5 mg of material was then pressed into a pellet and the CO FT-IR spectroscopy measurements were carried out by following the previously described measurement protocol.
UV–vis–NIR diffuse reflectance spectroscopy (UV–vis–NIR DRS) measurements were performed under in situ conditions by making use of a Varian Cary 500 spectrophotometer with a DRS accessory. The measurements were performed in the spectral range of 4000–45000 cm–1 with 33 ms data point scan time and spectral resolutions of 17 and 7 cm–1, in the 12500–45000 and 4000–12500 cm–1 spectral ranges, respectively. Two artifacts in the measured spectra were corrected for the detector/grating and light source changeovers at 12500 and 28570 cm–1, while the spectral feature appearing at 11250 cm–1 is due to an instrument artifact. For every measurement, the cell was loaded in a N2-filled glovebox (<2 ppm of H2O, O2), thereby keeping the samples from contact with atmospheric oxygen and water. The samples were measured against a Teflon-white measured in the same cell loaded with the same volume of 30 μm beads of Teflon powder. For measurement of the materials, 100 mg of catalyst material was loaded in a homemade cell. Subsequently, the required amounts of DEA were injected under a N2 flow of 10 mL min–1. After injection, the spectra were recorded until no further spectral changes were observed. Subsequently, the gas feed was switched to 10 mL min–1 C2H4 for gas-phase polymerization (Linde AG, C2H4, 99.9%). Spectra were recorded until no further changes occurred.
Scanning electron microscopy (SEM) micrographs of the MOF crystallites and the MIL-100(Cr) after reaction were recorded on a FEI Helios nanolab 600 Dual Beam with an Oxford Instruments Silicon Drift Detector X-Max energy-dispersive spectroscope. After the sample was deposited onto Al stabs with carbon tape (Electron Microscopy Sciences, Hartfield, PA, USA), the samples were sputtered with 22 nm of Pt(-Pd). Thereafter, imaging and EDX analysis were carried out at a beam of 15 kV and 0.1 nA. Micrographs of the polymer samples were recorded on a PhenomPro X microscope (FEI Company, USA), equipped with a CsB detector for backscattered electrons (BSE), operated at 10 kV. The samples were mounted on holey carbon tape supported on Al stubs that were not coated prior to measurements.
Differential scanning calorimetry (DSC) analyses were done with ca. 3–4 mg of polymer; each run was analyzed using a Texas Instrument Discovery DSC featuring an automatic sampler and TRIOS software. Each sample was heated from 298 to 473 K at a rate of 10 K min–1, held at 473 K for 2 min to erase the thermal history, and then cooled to 313 K at 1 K min–1 to ensure a slow recrystallization of the polymer. A second heating ramp was used to determine the melting temperature (Tm) and enthalpy (ΔHm), in which the sample was heated at 10 K min–1 to 473 K, before being cooled back to 298 K. The crystallinity of the polymer samples was determined assuming ΔHm0 = 293 J/g, for 100% crystalline ultrahigh-molecular-weight polyethylene (UHMWPE).
Gel permeation chromatography (GPC) was carried out on a Polymer Laboratories PL-GPC220 instrument, equipped with a PL BV-400 refractive index detector. The column set consisted of three Polymer Laboratories 13 μm PLgel Olexis 300 × 7.5 mm columns, and the calibration was performed with linear polyethylene (PE) and polypropylene (PP) standards. PP molar mass calibration was obtained after conversion from PE to PP using the Mark–Houwink constants.

2.3. Catalytic Testing

The degassed MOFs and complex 1 were tested for the polymerization of ethylene at 10 bar in the liquid phase. For the runs, 5 × 10–2 mmol of catalyst was introduced into a stainless-steel Parr reactor, together with Al:Cr ratio molar ratios of 100, 500, or 1000 of DEA in toluene (Sigma-Aldrich, anhydrous, 99.8%) inside an Ar-filled glovebox (O2, H2O <2 ppm). The autoclave was connected to an ethylene (Linde AG, 99.9%) line, the system was evacuated and flushed with ethylene three times before the cell was pressurized to 10 bar at 298 K, and the mixture was mechanically stirred at 1000 rpm. The cell was depressurized of ethylene after 1 h of reaction, the autoclave was cooled to 195 K using an acetone/dry ice bath, and the pyrophoric materials were quenched using acidified (37 wt % HCl(aq), Merck KGaA) methanol. The solid polyethylene was filtered, rinsed with MeOH (98%, VWR International), and dried under high vacuum overnight. The catalyst activity was based on the weighed polymer product.

3. Results and Discussion

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MIL-100(Cr) and MIL-101(Cr) frameworks are built up with chromium cations in an octahedral coordination forming the so-called chromium oxo-bridged trimer units, i.e. [(Cr33-O)], bonded to trimesic acid (H3BTC) or terephthalic acid (H2BDC) for MIL-100(Cr) or MIL-101(Cr), respectively. Coordinatively unsaturated positions (CUS) on the Cr3+ cations can be generated by removing the ligand in the axial position (typically nitrate, halide, hydroxy, or carboxylate anions arising from the synthesis) upon thermal treatment of the solid under vacuum. (47) In order to be able to solely compare the effects of MOF topology and exclude the presence of residual potential poisons, we carried out an anion exchange with Cl ions. Although the structure exhibits well-defined Cr3+ ions, the nature of the metal active sites upon addition of alkylating agents, such as diethylaluminum chloride (DEA), is not well understood. In order to verify that, isoreticular MIL-100(Cr) and MIL-100(Cr) were prepared following standard protocols and their crystallinity, purity, porosity, and morphology confirmed by means of X-ray diffraction (XRD), N2 adsorption at 77 K, thermogravimetric analysis (TGA), and scanning electron microscopy (SEM) (Sections 1–5 in the Supporting Information), respectively. The materials were subsequently impregnated with DEA and studied by XRD.

3.1. Structural Stability and Active Sites

XRD patterns of the materials after reaction with DEA, contact with ethylene at 298 K, and subsequent gentle quenching in air were obtained in order to study the stability of the MOFs upon contact with the cocatalyst. For this purpose, ca. 10 mg of activated MIL-100(Cr) and MIL-101(Cr) was mixed with DEA in an Ar-filled cell. Then, a 2 mL min–1 stream of air was flowed for 30 min at 298 K through the cell to quench any unreacted organoaluminum species. In Figure 1a, it can be seen that although the material is diffracting X-rays less intensely, the main XRD peaks at 2.36, 3.97, 4.64, and 4.89°, corresponding to the (220), (311), (222), and (400) reflections, respectively, are still present, indicating that the MOF structure is partially retained. Even after ethylene was flowed through the cell, the material did not show significant changes or the presence of a polymeric material. In contrast, the XRD patterns in Figure 1b show that the reaction of MIL-101(Cr) with DEA resulted in a complete loss in crystallinity, as none of the main reflections are present and only an amorphous pattern remains.

Figure 1

Figure 1. XRD patterns of (a) MIL-100(Cr) and (b) MIL-101(Cr) as synthesized (red), after contact with 125 equiv of DEA (Al:Cr = 100) (blue), and after ethylene was flowed at 298 K for 15 min (pink). The asterisk (*) indicates the formation of some high-density polyethylene (HDPE). Insets show the area with the main XRD reflections of the crystalline MOF.

This observation can be explained by a cleavage of the Cr–O bonds by the cocatalyst, resulting in the formation of defects, reduced and alkylated Cr, and linker sites as well as alumina or aluminum oxide like species. When ethylene was passed through the cell, a white solid, which was confirmed to be traces of HDPE (Supporting Information, Section S6 and Figure S11) appeared. This demonstrated that some of the Cr sites are able to form a polymer in the gas phase, unlike the case for the MIL-100(Cr) structure.
In order to understand if different Cr sites were present in the MOF frameworks after degassing and upon addition of DEA, in situ FT-IR spectroscopy experiments with CO as a probe molecule were carried out. In line with the literature, different types of sites were observed when the material was dried at 423 or 623 K. (47) First of all, in Figure 2a–c, spectra of MIL-100(Cr) dosed with CO show the presence of very few coordinatively unsaturated sites [Cr3+···CO] when degassing was done at 423 K (at 2188 cm–1). A very intense band at 2154 cm–1 (next to that at 2136 cm–1 of physisorbed CO) indicates that most sites were still hydroxylated. Interestingly, a small feature at 2106 cm–1 was observed, which may correspond to the formation of extraframework or defectively coordinated Cr cations during synthesis or degassing. We tentatively ascribe this feature to partially reduced Cr3+/2+(CO)xXy (X = Cl, NO3, OH, or H2BTC) species, as they are typically present at such low wavenumber regions. (48−52)

Figure 2

Figure 2. FT-IR spectra with CO as a probe molecule measured at 85 K of (a–c) MIL-100(Cr) and (d–f) MIL-101(Cr) after activation under vacuum (10–5 mbar) for 16 h at 423 K, at 623 K, and after impregnation with diethylaluminum chloride (DEA) (with Al:Cr molar ratio 100) and CO dosage (0–1 mbar) at 85 K. Degassed MIL-100(Cr) was subtracted as a reference in (b) and (c). MIL-101(Cr) was subtracted as a reference spectrum in (e) and (f).

The presence of the main interaction OC···Cr3+(MOF) bands at 2200–2180 cm–1 makes it impossible to distinguish the presence of Cr2+ sites by using this region. This feature is observed at 2090 cm–1 when the sample is degassed at 623 K, indicating that indeed the treatment has a certain effect on the coordination environment of the Cr cations. Moreover, the band at 2188 cm–1 is slightly shifted toward 2191 cm–1 and is much more intense, indicating that a much larger number of Lewis acid Cr3+ sites appear upon degassing at higher temperature. Addition of the organo-aluminum compound results in a strong modification of the baseline as well as in the formation of a shoulder at 2200 cm–1, which indicates an abstraction of additional counterions from the Cr sites. No further indications of the presence of Cr2+ sites are present, suggesting that they are alkylated and are not available for binding with CO as probe molecule. When an identical treatment was carried out on MIL-101(Cr), a number of differences were observed. First of all, when the material was degassed at 423 K, a higher fraction of Lewis Cr3+ sites was observed as a band at 2190 cm–1, and a very small amount of hydroxylated Cr sites (seen as a broad shoulder at ca. 2167 cm–1) was probed. Again, a small feature (inset in Figure 2d) appeared at lower wavenumbers (2090 cm–1) together with another feature at 2062 cm–1 after dosing CO, indicating Cr2/3+(CO)x species. It is important to remark that, in this case, two types of Cr carbonyl sites are formed, indicating that not one but multiple reduced Cr sites appear. When the material was degassed at 623 K, a trend similar to that for MIL-100(Cr) was seen, meaning more (and more acidic) Lewis acid sites and hydroxylated Cr3+ sites are present. The small spectral feature at 2090 cm–1 remained unchanged, while that at 2062 cm–1 became less intense and was shifted to 2057 cm–1, indicating that the thermal treatment results in a higher degree of reduction (i.e., a red shift indicates an enhanced π back-donation of the Cr sites). (53)
Addition of DEA to MIL-101(Cr) has a dramatic effect on the spectral features (Figure 2f). The band corresponding to Lewis Cr3+ sites broadens significantly, indicating the presence of a wide variety of different highly acidic Cr3+ sites (e.g., extraframework cations, embedded in the lattice), as they are quickly saturated at low CO pressures. Similarly, the feature at 2065 cm–1, corresponding to the Cr2+(CO)x species, broadens and increases in intensity dramatically. Again, a large number of differently coordinated Cr2+ sites are formed upon reaction with the alkylating cocatalyst. It is unclear whether any of the carbonyl adducts are binding atop or bridging at this moment. Decomposition of the MIL-101(Cr) framework by DEA results in another unassigned strong spectroscopic feature at 2261 cm–1. Our interpretation of the Cr reduction is further supported by the in situ UV–vis–NIR DR spectra recorded after addition of DEA (Figure 3).

Figure 3

Figure 3. (a) Diffuse reflectance (DRS) spectra in the vis–NIR region for degassed MIL-100(Cr) (red), after injection of 125 equiv of diethylaluminum chloride (DEA) (blue) and after 15 min (pink). (b) Deconvolution of the UV–vis–NIR DRS spectrum after injection of DEA showing different Cr species. The inset in (b) shows the presence of small amounts of Cr2+ species (both Oh and Th geometries). Green lines show the residual values of the fitting procedure. (c) DRS spectra in the UV–vis–NIR region after flowing ethylene (10 mL min1) at 298 K and 1 bar for 1 h into the cell (from dark blue (t = 0) to red (t = 60 min)). The inset shows bands where polyethylene C–H combination bands should appear if polymerization occurred. (d) DRS spectra in the vis–NIR range of activated MIL-101(Cr) (red), after injection of 125 equiv of DEA (blue) and after 15 min (pink). (e) Deconvolution of the spectrum after injection of DEA showing the different Cr species. The inset in (e) shows the presence of small amounts of Cr2+ species (only Oh geometry). Green lines show the residual of the fitting procedure. (f) DRS spectra in the NIR region after flowing ethylene (10 mL min1) at 298 K and 1 bar for 1 h into the cell (from dark blue (t = 0) to red (t = 60 min)), showing the bands of crystalline PE forming over time. The inset shows additional combination bands of the polymer CH2 groups, indicating polymer formation in contrast to the case of (c).

The bands observed in the spectrum of activated MIL-100(Cr) (red spectrum, Figure 3a) correspond to characteristic bands for octahedral (Oh) Cr3+ species with an oxide-like ligand environment at 24000 and 16000 cm–1 of the Cr trimers. (54,55) The t2g → t2geg1 transition, split into the 4T1g ← A2g and the 4T2g4A2g transitions, relate to the higher and lower energy bands, respectively. After addition of DEA (Figure 3a, blue spectrum), the DRS spectrum (Figure 3b) is characterized by two absorption bands at ∼11000–10000 cm–1, indicative of the presence of coordinatively unsaturated Cr2+ species, suggesting the formation of a few reduced chromium sites. This observation is in line with our previous CO-probe FT-IR spectroscopy results and previously mentioned literature. (42) Other relevant studies show that metal terephthalate MOFs containing exclusively Cr3+ show no absorption below 13000 cm–1 (even for CrTh geometries), supported by both time-dependent density functional theory (TD-DFT) calculations and UV–vis experiments, suggesting that indeed the DEA acts as a reducing agent of Cr cations. (56) The presence of some [Cr3+···OH2] species even after thermal treatment is verified by the absorption band at ∼5220 cm–1 (see Figure S12b), which corresponds to the O–H combination band vOH + δOH, confirming the presence of a few remaining nondehydroxylated Cr sites (as previously shown with FT-IR spectroscopy). (47) Moreover, we observed a decrease in the intensity of the ligand to metal charge transfer (LMCT) bands of π* → d transitions at 45000–38000 cm–1 (Figure S12a). This can be ascribed to a partial degradation of the MOF framework caused by a cleavage of the Cr–O bonds, which react with the organo-aluminum species. Flowing ethylene over the activated MOF results in a decrease in the intensity of the characteristic Cr2+ absorption bands (located at ca. 12000–10000 cm–1) shortly after, although no significant changes are seen in the C–H region, indicating no polyethylene formation. Again, different species were observed for MIL-101(Cr) after both addition of the cocatalyst and addition of ethylene. A much more pronounced decrease in the intensities of the LMCT bands occurred (Figure S13a), corroborating the structural collapse observed in XRD patterns. Deconvolution of the DRS spectrum, as shown in Figure 3e, indicates the presence of reduced Cr2+ sites, although only octahedral species are formed in this case. Furthermore, the main contribution of the low-energy Cr3+Oh is shifted toward ca. 15000 cm–1, indicating changes in the nature of the Cr3+ sites as well, in agreement with the broad band observed in the related FT-IR data. The peaks at 4180, 4250, and 4325 cm–1, which correspond to C–H combination bands, indicate alkylation of the MOF. When ethylene was introduced in the cell, the formation of HDPE was steadily detected by the sharpening of the C–H combination bands (Figure 3e).
An increase in the bands at ca. 8400, 5900, and 4500–4000 cm–1 with increasing time corroborates the formation of a solid phase. Indeed, flowing ethylene at slightly higher temperature (313 K) for 1 h into the cell, after activation with 100 equiv of DEA, resulted in the formation of significant amounts of HDPE from the gas phase, as confirmed by XRD (Figure S11). In brief, the DRS data show that, in spite of having the same structural motifs (i.e. carboxylates and Cr3(μ-O) trimers), each MOF forms different Cr3+ and Cr2+ species with similar coordination environments after addition of DEA, and only MIL-101(Cr) is capable of producing some polymer.
In order to compare both MOFs as active catalyst materials, the catalytic polymerization of ethylene in a liquid-phase reactor (in toluene) at 10 bar was carried out. Three different amounts of cocatalyst (i.e., Al:Cr = 100, 500, 1000) were tested, in order to understand the influence of the cocatalyst on the activity and final materials produced. As we hypothesized, Table 1 shows that, despite both MOFs possessing identical topology, MIL-100(Cr) is practically unable to catalyze the formation of polyethylene, regardless of the Al:Cr ratio used. In contrast, MIL-101(Cr) showed high activity (i.e., 15.4 kg PE (mol Cr)−1 h–1 bar–1) for a Al:Cr ratio of 100. Higher amounts of cocatalyst were detrimental for the performance under the same reaction conditions (i.e., ∼ 4–5 kg PE (mol Cr)−1 h–1 bar–1), as previously reported for organoaluminum alkylated Phillips systems. (57) In order to further understand if pore confinement and anchoring of the Cr trimer sites have an influence on the active sites, the coordination complex 1 (see Section S1 for details on the synthesis) was used as a homogeneous counterpart. A parallel trend can be observed in activity (Table 1), indicating that the active sites present after addition of DEA are rather similar to those of MIL-101(Cr). The physical properties (melting temperature, Tm; heat of fusion, ΔHm) of crystalline HDPE are governed by its molecular structure, which is very much determined by the catalytic sites. DSC analyses (Table 1 and Section S8 and Figure S14) were carried out to compare the properties of the obtained materials. As can be concluded from Table 1, both MIL-101(Cr) and complex 1 show the typical %X, Tm and ΔHm ranges for HDPE with low branching. To elucidate if the cocatalyst led to Cr leaching of MIL-101, the activity of the solution obtained after mixing DEA with MIL-101(Cr) catalyst was evaluated, showing that indeed some HDPE was formed, with properties similar to those of complex 1. This indicates the same active sites for both catalyst materials: i.e., trimers dissolved in toluene. However, to our surprise, MIL-100(Cr) was inactive under the same conditions.
Table 1. Catalytic Activity of the Different Materials under Study, Including the Physicochemical Properties of the High-Density Polyethylene Products Obtained after Performing the Ethylene Polymerization Experiments
catalystAl:CrbactivitycTm (K)ΔHm (J/g)%XdMw (103 kDa)PDIe
1a10013.0408.3182.162.21.88.3
 5006.15407.7169.157.71.510.6
 10004.12408.2181.962.11.215.7
MIL-100(Cr)a,f1001.3 × 10–3<0.03    
 5000.4 × 10–3<0.03    
 10002.1 × 10–3<0.03    
MIL-101(Cr)a10015.4408.5189.764.71.127.0
 5004.71410193.165.90.922.6
 10005.41410.6182.962.40.8518.0
MIL-101(Cr)a,g5000.63409.3187.664.01.411.2
a

Reaction conditions unless specified otherwise: 1 h at 10 bar of C2H4 in 20 mL of toluene at 298 K in a 35 mL Parr-autoclave reactor.

b

Al:Cr molar ratio.

c

Activity: kg PE (mol Cr)−1 h–1 bar–1.

d

In comparison to 293 J/g for 100% crystalline UHMWPE.

e

Determined by GPC calibrated with PE and PP standards.

f

Not enough polymer product for analysis. Experiments at 10, 20, 30, and 40 bar showed no activity.

g

MOF/AlEt2Cl was stirred together in toluene for 30 min and filtered into reactor before reaction.

Accordingly, GPC analysis (Table 1 and Section S9) shows that Mw ≈ (0.85–1.8) × 103 kDa for the polymers produced, i.e. lower-end to mid-sized HDPE chains, in line with the DSC data. Nevertheless, average molecular weights (Mw) were slightly higher when nonporous complex 1 was used instead of the zeotypic MIL-101(Cr), following the activity trend. Different correlations between catalyst porosity and Mw have been observed in the past. (58,59) We envision a process in which Cr trimers that leach and remain entrapped in the pores lead to different (probably shorter) polymer chains. This is not the case when complex 1 is used: chains can grow with no physical constraints, only limited by chain transfer reactions or catalyst deactivation processes. In our case, the high-MW shoulder is more prominent for low Al loading and complex 1 catalyst. GPC of the HDPE obtained with complex 1 shows longer tails (log Mw ≈ 6.5 in Figures S15–S17), which may be associated with enhanced chain transfer reactions, as demonstrated by similar trends with increasing cocatalyst amounts (Section S9 in the Supporting Information) in the experiments in which MIL-101(Cr) was used. Thus, we hypothesize that the variety of chain lengths is related not only to different active sites, MOF-embodiment, or solubilization but also to the presence of increasing cocatalyst amounts. A very high Al:Cr may result in an overalkylation, chain termination promotion, or simply alumina coverage of the growing chains. Again, molecular weight distributions (MWDs) and polydispersity index (PDI) values of the polymer obtained after filtration of the MIL-101(Cr) fully correlate to that of the material obtained with 1. This indicates that the active sites consist of alkylated Cr sites derived from the trimers in solution. Recent studies have shown multiple possibilities (e.g. metallacycle, Green–Rooney, Cossee–Arman) for the initiation mechanism of ethylene insertion in similar Cr systems. (60,61) However, the agreement is that chain growth in Cr-based Phillips catalysts operates mostly via the Cossee–Arlman mechanism. (2,62) In the case of MIL-100(Cr) Liu et al. described a mechanism involving multiple metal centers acting via a metallacycle mechanism, yielding short (C6–C12) α-olefins. (42) With the results previously described in this work, we propose that the active species for MIL-101(Cr) and 1 consist of Cr-alkyl sites formed by partial degradation of the lattice that lead to the formation of active sites that can insert ethylene, as described in Scheme 1. These Cr sites arise from the Cr trimers being most likely Cr3+ or Cr2+ sites (according to the spectroscopy study), although the oxidation state and coordination geometry still remain elusive. The inability of MIL-100(Cr) to fracture would explain the high activity in the formation of α-olefins.

Scheme 1

Scheme 1. Tentative Activation of Cr Sites by Diethylaluminum Chloride (DEA) and Subsequent Ethylene Insertion and Polymerization in MIL-101(Cr) Materials

3.2. Polymer Morphology

Control over the particle morphology is crucial for large-scale synthesis of polyethylene. (1,2,24,25) Regardless of the catalytic process employed, a number of issues such as reactor fouling, heat transfer, and product properties have to be taken into account. As already mentioned, Cr-based catalysts are typically supported onto solid oxides that crumble during ethylene polymerization, allowing the necessary chain growth. The above results led us to evaluate the ability of both MIL-100(Cr) and MIL-101(Cr) to generate structured polyethylene upon fragmentation of the MOF catalysts. Surprisingly, Figure 4a,b shows that, under identical reaction conditions, MIL-101(Cr) generates spherical beads of polyethylene, in contrast to MIL-100(Cr) (Figure 4c,d), which produces nanosized (<1 μm), ill-shaped material. These findings show that not only is MIL-101(Cr) active in ethylene polymerization but also that its use as a catalyst confers to the polymer a certain architecture at the macroscale. Experiments with different Al:Cr ratios show that the templating effect is retained in every case, with a minimal effect on the size distribution (Figure S17). Analogously, a similarly poorly shaped material was covering MIL-100(Cr) crystallites for all the Al:Cr ratios tested, indicating no significant chain growth under these conditions.

Figure 4

Figure 4. Scanning electron microscopy (SEM) micrographs of the polymer product obtained with (a, b) MIL-101(Cr), (c, d) MIL-100(Cr) (note that only nanosized crystallites are observed at this magnification), complex 1 (e, f), and the leached Cr from MIL-101(Cr) (g, h). Conditions: Al:Cr mol ratio of 100, diethylaluminum chloride (DEA), T = 298 K, p = 10 bar of C2H4, t = 1 h.

We explain this difference on the basis of our previous XRD analysis, which indicated the total collapse of MIL-101(Cr). This enables the Cr active sites to grow polymer chains in the solvent medium, in contrast to MIL-100(Cr), which retains its crystalline structure, preventing the crystallites from fracturing upon ethylene insertion. Thus, the obtained SEM images indicate that MIL-101(Cr) acts as a sacrificial template, in which the catalytically active species reside and that is later covered on polyethylene during the reaction, leading to the observed polymer beads.
The SEM images of the polymer obtained with catalytic complex 1 show randomly oriented, intergrown polymer fibers of ca. 3–5 μm thickness (for the same Al:Cr ratios; Figure S17), indicating that, in addition to the Cr trimer units, a solid scaffold is required to control the chain growth. In order to confirm its role as a structural template and discriminate it from possible leached species that polymerize in solution, the SEM images of the polymer recovered from toluene filtered after suspending DEA-activated MIL-101(Cr) were recorded. Figure 4g,h shows fibers very similar to those obtained with complex 1, proving that the sole presence of Cr trimers in solution is not enough to obtain the morphologically controlled polymer. SEM images in Figure 5 and Figure S19 of the recovered MIL-100(Cr) solid after reaction with 500 equiv of cocatalyst corroborate our hypothesis. After filtration from the toluene solvent, most of the MOF crystallites appeared intact (compare to SEM in Figure S9), and only a few polymer fibers arising from the pores were observed. Some species that have leached into solution (the strong alkylating agent causes partial degradation of MIL-100, as shown by XRD) formed polyethylene layers that covered the MOF (Figure S19). This has been previously observed in other catalysts supported in porous polymers. (59)

Figure 5

Figure 5. Scanning electron microscopy (SEM) micrographs of MIL-100(Cr) after reaction (10 bar of C2H4, 298 K, 500 equiv of DEA, toluene, 1 h) at high magnification, showing MIL-100(Cr) crystallites still intact. The arrows in the inset image indicate polymer fibers of MOF crystallites that were not able to fracture. However, no evident signs of polymerization around the MOF crystallites, into shaped beads as is the case for MIL-101(Cr), were observed. In Figure 5, the inset shows a few polymer fibers that emerge from certain MOF crystallites. This is in stark contrast with MIL-101(Cr) and complex 1, and it evidences the inability of MIL-100(Cr) to crumble upon ethylene insertion.

Although Cr–O bond strength has been argued as a possible reason for differences in reactivity (as it may not allow for the alkylation of Cr), X-ray diffraction studies have shown that Cr–O distances are ca. 1.975 Å for all catalysts, indicating very similar bonding strengths. On the other hand, porosity has been shown to greatly affect activity for ethylene polymerization in Cr-based systems. Differences in activity are due to the porosity of each material. It is well-known that support and catalyst porosity have a tremendous effect on polymer production. (2)
It is generally accepted that at least Vp ≥ 1.0 cm3 g–1 is necessary in silica in order for the support to crumble upon chain growth. Despite the different chemical and physical nature in comparison to silica and its high porosity, MIL-100 showed a pore volume (Vp = 0.81 cm3 g–1) below that threshold (Figure S3). In contrast, MIL-101 (Vp = 1.27 cm3 g–1) was well above the threshold (Figure S4), pointing to a critical effect on polymerization activity. As pointed out by McDaniel, it is not the difference in pore volume but the fragility (which may arise from this difference in pore volume and seems to be the cause for this difference) that prevents higher polymerization activity. In fact, not only a difference in pore volume but also a difference in pore diameter and window exists. While MIL-100 has two types of cages, of 25 and 29 Å diameter (with pore windows 5 and 8.6 Å, respectively), (43) MIL-101 exhibits diameters of 27 and 34 Å (with 11.6 and 16 Å windows). (44) This difference in pore diameter, specifically the presence of the larger 34 Å cages, seems to be critical for ethylene polymerization. We argue that chain growth occurring in that specific cage is enough to tear apart MIL-101 crystallites during the process, giving rise to new active sites that further polymerize ethylene. DFT pore size distributions shown in Figure 6 clearly illustrate the difference in pore diameter cages between both MOFs.

Figure 6

Figure 6. Density functional theory (DFT) pore size distributions of both MOFs calculated from the experimental N2 adsorption isotherms at 77 K.

An alternative explanation for these differences in reactivity may be the low temperature, i.e. 298 K, at which the polymerization was conducted, which would be insufficient to collapse the MIL-100(Cr) framework.
For coordination complex 1, it readily dissolves in the reaction medium (toluene), acting as a homogeneous catalyst with no need of fracturing, as observed in the SEM imaged randomly oriented polymer fibers.
In Figure 7, a summary of the different activities and morphologies that are obtained in ethylene polymerization under the studied conditions is presented. MIL-101(Cr) is a competent catalyst that, although it performs below commercial Philips benchmarks, is able to structure the polymer at the microscale, while producing high-molecular-weight PE with relatively narrow PDI (orange). In contrast, MIL-100(Cr) (green) is unable to fracture and produce polymer, while complex 1 results in a nonstructured polymer (purple).

Figure 7

Figure 7. (a) MIL-100(Cr) is unable to fracture upon polyethylene formation, resulting in low catalytic activity. (b) MIL-101(Cr) is degraded and partially leaches Cr clusters into the solution upon addition of the cocatalyst, leading to different morphologies. (c) Coordination complex 1 in solution generates polymer fibers, as the chain growth is not templated by any solid support.

4. Conclusions

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It was found that the MOF material MIL-101(Cr) can be used as an active morphology template in the catalytic polymerization of ethylene. In contrast, the isoreticular MIL-100(Cr) material is unable to reach significant ethylene polymerization activities due to the high stability of the crystallites against fragmentation. XRD studies revealed that, while MIL-100(Cr) is still crystalline after addition of the organo-aluminum cocatalyst (i.e., diethylaluminum chloride, DEA), MIL-101(Cr) completely collapses, leading to an amorphous solid material. Furthermore, in situ FT-IR spectroscopy with CO as a probe molecule and UV–vis–NIR DRS spectroscopy show that different reduced and alkylated Cr sites are formed for each MOF, further indicating different stabilities toward the cocatalyst DEA. The exact nature of the active Cr species (as in the case of the long-debated Phillips system) is not yet fully understood, but experiments with the putative homogeneous coordination complex showed trends in reactivity in the production of HDPE similar to those of MIL-101(Cr), suggesting that alkylated Cr sites are the main ethylene polymerization sites. In contrast, MIL-100(Cr) shows very low polymerization activity, mostly producing gaseous and liquid olefins instead.
SEM studies revealed that, in addition to catalyzing chain growth, MIL-101(Cr) can also act as a structure modulator for the polymer material obtained, leading to the formation of spherical micrometer-sized polyethylene beads. Again, control experiments with the homogeneous complex 1 confirm this hypothesis, as the coordination complex catalyst 1 produces interwoven polymer fibers in a random orientation. In other words, Cr-based MOF materials have the ability to act as a self-sacrificial template for structuring polymer materials while they form in the internal pore structure over active ethylene polymerization sites. We foresee that our research will foster the design of new polyolefin architectures, as well as expand our understanding of highly stable MOFs (i.e. MIL-100 and 101) upon reaction with reactive activators for the selective production of short-chain olefins, such as 1-octene and 1-hexene.

Supporting Information

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The Supporting Information is available free of charge on the ACS Publications website at DOI: 10.1021/acscatal.9b00150.

  • Data and experimental details for the synthesis and characterization of coordination complex 1, experimental details on XRD, N2 adsorption at 77 K, TGA-MS, and SEM of the MIL-100 and MIL-101 materials, characterization of polyethylene obtained from the gas phase by XRD with MIL-101(Cr), more detailed UV–vis–NIR DRS experiments upon addition of DEA, and details on the physicochemical properties of the polymer materials obtained by DSC, GPC, and additional SEM images (PDF)

Terms & Conditions

Most electronic Supporting Information files are available without a subscription to ACS Web Editions. Such files may be downloaded by article for research use (if there is a public use license linked to the relevant article, that license may permit other uses). Permission may be obtained from ACS for other uses through requests via the RightsLink permission system: http://pubs.acs.org/page/copyright/permissions.html.

Author Information

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  • Corresponding Author
  • Authors
    • Miguel Rivera-Torrente - Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
    • Paul D. Pletcher - Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
    • Maarten K. Jongkind - Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
    • Nikolaos Nikolopoulos - Inorganic Chemistry and Catalysis, Debye Institute for Nanomaterials Science, Utrecht University, Universiteitsweg 99, 3584 CG Utrecht, The Netherlands
  • Notes
    The authors declare no competing financial interest.

Acknowledgments

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T. N. Ran (Utrecht University, UU) is thanked for the ESI-MS measurements, while C. Hernández-Mejía (Utrecht University, UU) is acknowledged for help during the in situ FT-IR spectroscopy experiments. We also thank N. Friederichs (SABIC) for the GPC measurements. N. Maaskant (UU), R. Pluijm (UU), G. de Reijer (UU), and P. Dolata (UU) are acknowledged for their help with sample preparation. This project has received funding from the European Union Horizon 2020 research and innovation program under the Marie-Sklodowska-Curie grant agreement 641887 (DEFNET) as well as funding from TKI Chemistry (The Netherlands).

References

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  • Abstract

    Figure 1

    Figure 1. XRD patterns of (a) MIL-100(Cr) and (b) MIL-101(Cr) as synthesized (red), after contact with 125 equiv of DEA (Al:Cr = 100) (blue), and after ethylene was flowed at 298 K for 15 min (pink). The asterisk (*) indicates the formation of some high-density polyethylene (HDPE). Insets show the area with the main XRD reflections of the crystalline MOF.

    Figure 2

    Figure 2. FT-IR spectra with CO as a probe molecule measured at 85 K of (a–c) MIL-100(Cr) and (d–f) MIL-101(Cr) after activation under vacuum (10–5 mbar) for 16 h at 423 K, at 623 K, and after impregnation with diethylaluminum chloride (DEA) (with Al:Cr molar ratio 100) and CO dosage (0–1 mbar) at 85 K. Degassed MIL-100(Cr) was subtracted as a reference in (b) and (c). MIL-101(Cr) was subtracted as a reference spectrum in (e) and (f).

    Figure 3

    Figure 3. (a) Diffuse reflectance (DRS) spectra in the vis–NIR region for degassed MIL-100(Cr) (red), after injection of 125 equiv of diethylaluminum chloride (DEA) (blue) and after 15 min (pink). (b) Deconvolution of the UV–vis–NIR DRS spectrum after injection of DEA showing different Cr species. The inset in (b) shows the presence of small amounts of Cr2+ species (both Oh and Th geometries). Green lines show the residual values of the fitting procedure. (c) DRS spectra in the UV–vis–NIR region after flowing ethylene (10 mL min1) at 298 K and 1 bar for 1 h into the cell (from dark blue (t = 0) to red (t = 60 min)). The inset shows bands where polyethylene C–H combination bands should appear if polymerization occurred. (d) DRS spectra in the vis–NIR range of activated MIL-101(Cr) (red), after injection of 125 equiv of DEA (blue) and after 15 min (pink). (e) Deconvolution of the spectrum after injection of DEA showing the different Cr species. The inset in (e) shows the presence of small amounts of Cr2+ species (only Oh geometry). Green lines show the residual of the fitting procedure. (f) DRS spectra in the NIR region after flowing ethylene (10 mL min1) at 298 K and 1 bar for 1 h into the cell (from dark blue (t = 0) to red (t = 60 min)), showing the bands of crystalline PE forming over time. The inset shows additional combination bands of the polymer CH2 groups, indicating polymer formation in contrast to the case of (c).

    Scheme 1

    Scheme 1. Tentative Activation of Cr Sites by Diethylaluminum Chloride (DEA) and Subsequent Ethylene Insertion and Polymerization in MIL-101(Cr) Materials

    Figure 4

    Figure 4. Scanning electron microscopy (SEM) micrographs of the polymer product obtained with (a, b) MIL-101(Cr), (c, d) MIL-100(Cr) (note that only nanosized crystallites are observed at this magnification), complex 1 (e, f), and the leached Cr from MIL-101(Cr) (g, h). Conditions: Al:Cr mol ratio of 100, diethylaluminum chloride (DEA), T = 298 K, p = 10 bar of C2H4, t = 1 h.

    Figure 5

    Figure 5. Scanning electron microscopy (SEM) micrographs of MIL-100(Cr) after reaction (10 bar of C2H4, 298 K, 500 equiv of DEA, toluene, 1 h) at high magnification, showing MIL-100(Cr) crystallites still intact. The arrows in the inset image indicate polymer fibers of MOF crystallites that were not able to fracture. However, no evident signs of polymerization around the MOF crystallites, into shaped beads as is the case for MIL-101(Cr), were observed. In Figure 5, the inset shows a few polymer fibers that emerge from certain MOF crystallites. This is in stark contrast with MIL-101(Cr) and complex 1, and it evidences the inability of MIL-100(Cr) to crumble upon ethylene insertion.

    Figure 6

    Figure 6. Density functional theory (DFT) pore size distributions of both MOFs calculated from the experimental N2 adsorption isotherms at 77 K.

    Figure 7

    Figure 7. (a) MIL-100(Cr) is unable to fracture upon polyethylene formation, resulting in low catalytic activity. (b) MIL-101(Cr) is degraded and partially leaches Cr clusters into the solution upon addition of the cocatalyst, leading to different morphologies. (c) Coordination complex 1 in solution generates polymer fibers, as the chain growth is not templated by any solid support.

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    • Data and experimental details for the synthesis and characterization of coordination complex 1, experimental details on XRD, N2 adsorption at 77 K, TGA-MS, and SEM of the MIL-100 and MIL-101 materials, characterization of polyethylene obtained from the gas phase by XRD with MIL-101(Cr), more detailed UV–vis–NIR DRS experiments upon addition of DEA, and details on the physicochemical properties of the polymer materials obtained by DSC, GPC, and additional SEM images (PDF)


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