Tailoring Hexagonal Gibbsite Single Crystal Nanoplatelets for Ethylene Polymerization and Nanocomposite Formation on MAO-Free Heterogeneous Bis(imino)pyridine Iron(II) Catalyst

Abstract

Ultrathin single crystal γ-Al(OH)₃ (Gibbsite) nanoplatelets with average thickness <20 nm and length <800 nm, pretreated with trimethylaluminum (TMA), represent highly efficient activators and supports bis(imino)pyridine iron (II) (FeBIP) complex to produce high density polyethylene (HDPE) as well as gibbsite/HDPE nanocomposites in exceptionally high yields. Opposite to both methylaluminoxane (MAO)-activated homogeneous FeBIP catalyst and heterogenous silica-supported single site catalysts, no addition of MAO is required. At low TMA/Fe = 50 molar ratio, the superior catalyst activity (up to 6500 kg mol^-1 h^-1 bar^-1 ) of FeBIP@TMA@Gibbsite is paralleled by controlled polyethylene particle growth without encountering reactor-fouling problems typical for homogeneous catalysts. TMA@Gibbsite is compared with other AlR₃ @Gibbsite activators. The Al/Fe molar ratio governs catalyst activity as well as molar mass, molar mass distribution, and thermal properties of polyethylene. Moreover, hexagonal gibbsite nanoplatelets are uniformly dispersed in polyethylene to yield agglomerate-free polyethylene/gibbsite nanocomposites.

Keywords: catalysis; ethylene polymerization; gibbsite; iron catalysts; nanotechnology.