Single-site catalysts revolutionized the polyolefin manufacturing industry and research with their ability to make polymers with uniform microstructural properties. Several of these catalysts are currently used commercially to produce commodity and differentiated-commodity resins. The key to their rapid success and industrial implementation resides in the fact that they can be used without major modifications in the polymerization reactors that previously used heterogeneous Ziegler-Natta and Phillips catalysts. Since most of these industrial processes use slurry or gas-phase reactors, soluble single-site catalysts must be supported on adequate carriers that ensure not only high activity, but also the formation of polymer particles with the proper morphology and bulk densities. Metallocene catalysts have been supported on a variety of carriers, but supporting late transition metal catalysts has not been investigated in detail, despite their very interesting properties such as tolerance to polar comonomers and impurities, activity in the absence of MAO, and the formation of short chain branches by the chain walking mechanism. The research work of this PhD thesis intends to fill this gap, by developing supported late transition metal catalysts with high catalyst activities towards ethylene polymerization and good polymer particle morphology. The effects of catalyst structure and polymerization conditions on silica-supported nickel diimine catalysts are discussed in Chapter 3. Compared with the equivalent homogeneous catalysts, the covalently-attached supported catalysts had high activities, produced spherical polyethylene particles with good morphologies, and polyethylene with higher melting temperatures, higher molecular weight averages, and broader molecular weight distributions. Borates used as internal activators during the synthesis of these supported catalysts successfully activated the nickel diimine complexes. In Chapter 4, MgCl2/alcohol adducts are recrystallized with alkylaluminum compounds and used as catalysts supports for nickel diimine complexes functionalized with amine groups. Polymerization results were compared with those of the equivalent SiO2-supported nickel diimine catalysts. MgCl2-based supported nickel diimine catalysts had high catalyst activity without the use of activators, and it was possible to control polymer molecular weight averages by changing the support composition. Although linear low density polyethylene made with metallocenes offers superior mechanical properties such as excellent toughness, impact strength and clarity, it suffers from poor processability. To overcome some of these disadvantages, Chapter 5 introduces methods to produce bimodal polyethylene resins using supported hybrid early and late transition metal catalyst systems. The presence of short chain branches in the higher molecular weight component is attributable to the incorporation of alpha-olefin molecules by the metallocene sites, while the nickel diimine catalyst sites produce chains with a distribution of short chain branch sizes through the chain walking mechanism. Finally, in Chapter 6 supporting a nickel diimine catalyst onto organo-modified montmorillonite (MMT) to prepare polyethylene/clay nanocomposites through in-situ polymerization is described. The thermal properties and crystallinity of the nanocomposites could be controlled by varying the fraction of MMT in the nanocomposite, and the dispersion of the MMT layers in the polymer matrix were characterized by scanning electron microscopy (SEM) and transmission electron microscopy (TEM).

Single-site catalysts revolutionized the polyolefin manufacturing industry and research with their ability to make polymers with uniform microstructural properties. Several of these catalysts are currently used commercially to produce commodity and differentiated-commodity resins. The key to their rapid success and industrial implementation resides in the fact that they can be used without major modifications in the polymerization reactors that previously used heterogeneous Ziegler-Natta and Phillips catalysts. Since most of these industrial processes use slurry or gas-phase reactors, soluble single-site catalysts must be supported on adequate carriers that ensure not only high activity, but also the formation of polymer particles with the proper morphology and bulk densities. Metallocene catalysts have been supported on a variety of carriers, but supporting late transition metal catalysts has not been investigated in detail, despite their very interesting properties such as tolerance to polar comonomers and impurities, activity in the absence of MAO, and the formation of short chain branches by the chain walking mechanism. The research work of this PhD thesis intends to fill this gap, by developing supported late transition metal catalysts with high catalyst activities towards ethylene polymerization and good polymer particle morphology. The effects of catalyst structure and polymerization conditions on silica-supported nickel diimine catalysts are discussed in Chapter 3. Compared with the equivalent homogeneous catalysts, the covalently-attached supported catalysts had high activities, produced spherical polyethylene particles with good morphologies, and polyethylene with higher melting temperatures, higher molecular weight averages, and broader molecular weight distributions. Borates used as internal activators during the synthesis of these supported catalysts successfully activated the nickel diimine complexes. In Chapter 4, MgCl2/alcohol adducts are recrystallized with alkylaluminum compounds and used as catalysts supports for nickel diimine complexes functionalized with amine groups. Polymerization results were compared with those of the equivalent SiO2-supported nickel diimine catalysts. MgCl2-based supported nickel diimine catalysts had high catalyst activity without the use of activators, and it was possible to control polymer molecular weight averages by changing the support composition. Although linear low density polyethylene made with metallocenes offers superior mechanical properties such as excellent toughness, impact strength and clarity, it suffers from poor processability. To overcome some of these disadvantages, Chapter 5 introduces methods to produce bimodal polyethylene resins using supported hybrid early and late transition metal catalyst systems. The presence of short chain branches in the higher molecular weight component is attributable to the incorporation of alpha-olefin molecules by the metallocene sites, while the nickel diimine catalyst sites produce chains with a distribution of short chain branch sizes through the chain walking mechanism. Finally, in Chapter 6 supporting a nickel diimine catalyst onto organo-modified montmorillonite (MMT) to prepare polyethylene/clay nanocomposites through in-situ polymerization is described. The thermal properties and crystallinity of the nanocomposites could be controlled by varying the fraction of MMT in the nanocomposite, and the dispersion of the MMT layers in the polymer matrix were characterized by scanning electron microscopy (SEM) and transmission electron microscopy (TEM).

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The removal of trace amounts of acetylene in ethylene streams is a high-volume industrial process that must possess high selectivity of alkyne hydrogenation over hydrogenation of alkenes. Current technology uses metallic nanoparticles, typically palladium or platinum, for acetylene removal. However, problems arise due to the deactivation of the catalysts at high temperatures as well as low selectivities at high conversions. Pore expanded MCM-41 is synthesized via a two-step strategy in which MCM-41 was prepared via cetyltrimethylammonium bromide (CTMABr) followed by the hydrothermal treatment with N,N-dimethyldecylamine (DMDA). This material was washed with ethanol to remove DMDA, or calcined to remove both surfactants. PE-MCM-41 based materials were impregnated with palladium, gold, and palladium-gold nanoparticles. The removal of DMDA had an effect on both the conversion and selectivity, in which they were found to drop significantly. However, by using the bimetallic PdAu catalysts, higher selectivity could be achieved due to increased electron density.

The removal of trace amounts of acetylene in ethylene streams is a high-volume industrial process that must possess high selectivity of alkyne hydrogenation over hydrogenation of alkenes. Current technology uses metallic nanoparticles, typically palladium or platinum, for acetylene removal. However, problems arise due to the deactivation of the catalysts at high temperatures as well as low selectivities at high conversions. Pore expanded MCM-41 is synthesized via a two-step strategy in which MCM-41 was prepared via cetyltrimethylammonium bromide (CTMABr) followed by the hydrothermal treatment with N,N-dimethyldecylamine (DMDA). This material was washed with ethanol to remove DMDA, or calcined to remove both surfactants. PE-MCM-41 based materials were impregnated with palladium, gold, and palladium-gold nanoparticles. The removal of DMDA had an effect on both the conversion and selectivity, in which they were found to drop significantly. However, by using the bimetallic PdAu catalysts, higher selectivity could be achieved due to increased electron density.

Record high CO2 emissions in the atmosphere and the need to find alternative energy sources to fossil fuels are major global challenges. Conversion of CO2 into useful fuels like methanol and methane can in principle tackle both these environment and energy concerns. One of the routes to convert CO2 into useful fuels is by using supported metal catalyst. Specifically, metal atoms or clusters (few atoms large in size) supported on oxide materials are promising catalysts. Experiments have successfully converted CO2 to products like methanol, using TiO2 supported Cu atoms or clusters. How this catalyst works and how CO2 conversion could be improved is an area of much research. We used a quantum mechanical tool called density functional theory (DFT) to obtain atomic and electronic level insights in the CO2 reduction processes on TiO2 supported metal atoms and clusters. We modeled small Cu clusters on TiO2 surface, which are experimentally synthesizable. Our results show that the interfacial sites in TiO2 supported Cu are able to activate CO2 into a bent configuration that can be further reduced. The Cu dimer was found to be the most reactive for CO2 activation but were unstable catalysts. Following Cu, we also identified other potential metal atoms that can activate CO2. Compared to expensive and rare elements like Pt, Au, and Ir, we found several early and mid transition metals to be potentially active catalysts for CO2 reduction. Because the supported metal atom or cluster is a reactive catalyst, under reaction conditions they tend to undergo aggregation and/or oxidation to form larger less active catalysts. We chose Co, Ni, and Cu group elements to study their catalyst stability under oxidizing reaction conditions. Based on the thermodynamics of Cu oxidation and kinetics of O2 dissociation, we found that TiO2 supported Cu atom or a larger Cu tetramer cluster were the likely species observed in experiments. Our work provides valuable atomic-level insights into improving the CO2 reduction activities and predicts potential catalysts for CO2 reduction to valuable fuels.

Atom transfer radical polymerization (ATRP) which utilizes transition metal based catalysts is a versatile methodology for the synthesis of a wide spectrum of polymers with controlled architectures. However, high concentrations of soluble catalyst required in an ATRP process makes the final polymer colored and toxic. Thus, the catalyst removal/reduction/recycling remains a challenge in the field of ATRP. Supported catalysts on insoluble solids such as silica gel, polystyrene beads, etc. have been used in ATRP to facilitate the catalyst recovery and recycling. However, the ability of the supported catalysts to mediate a polymerization is substantially reduced due to their reduced mobility and leaching problems. In this thesis, we report a series of novel and recyclable physisorbed CuBr2/N, N, N’, N’’-pentamethyldiethylene-triamine supported catalytic systems operating in conjunction with hydration. Supported aqueous-phase catalysis (SAPC) for ATRP was evaluated for different inorganic (Na-clay, silica and zeolite) and organic (polysaccharides) supports. The hydrated physisorbed supported catalysts were used for the polymerization of benzyl methacrylate and methyl methacrylate using an activator generated electron transfer ATRP process. The catalyst was effectively retained on the surface of supports through hydration as was verified by UV-Vis measurements. The supported catalyst was easily removed from the polymerization by simple filtration process affording a colorless polymer solution. The polymerizations produced high conversion and colorless polymers with moderately narrow polydispersity indices (PDI). The catalyst maintained high activity during the recycling experiments. We also investigated the kinetic and mechanistic behavior of these solid supported polymerization systems. Based on split kinetics experiments and UV-Vis studies it was believed that the activation and deactivation processes took place at the diffused hydrated interface between the solid support and organic phase. The branched (stars and graft) polymers were also synthesized using Na-clay supported catalyst. The produced polymers had narrow PDI and good initiator efficiencies. The functionality of the star polymers was confirmed using 1H NMR and dilute solution properties. The synthesis of graft-copolymer was confirmed by 1H NMR and atomic force microscopy. This thesis demonstrates the successful use of SAPC for ATRP to produce contamination free linear and branched polymers with moderately narrow PDI and high recycling efficiency.

The study of catalysis is a fundamental aspect of chemical engineering, as its implications affect all chemical transformations. Traditionally, catalysis has been subdivided into two areas: homogeneous and heterogeneous catalysis. Homogeneous catalysis refers to single-sited catalysts that exist in the same phase as the reaction media. These catalysts tend to be highly active and selective but often difficult to recover and reuse. In contrast, heterogeneous catalysts are typically multi-sited catalysts that exist in a different phase from the reaction media. These catalysts tend to be less active and selective than their homogeneous counterparts. However, the vast majority of industrial scale catalysts are heterogeneous because they can be easily separated, making them easily implemented in continuous processes, allowing for efficient, large scale operations. Due to the limitations of traditional homogeneous and heterogeneous catalysts, researchers have increasingly investigated hybrid catalysts that incorporate aspects of homogeneous and heterogeneous catalysis. This is accomplished via immobilization of homogeneous catalyst analogues onto solid-phase supports, thereby preserving the activity and selectivity of homogeneous catalysts while allowing for facile recovery and reuse from the insoluble, heterogeneous support. A variety of systems is presented here including organic and organometallic catalysts immobilized on organic and inorganic supports. Five cases are included. The first discusses utilization of supported acid and base catalysts for use in one-pot cascade reactions. The second example illustrates use of silica-coated magnetic nanoparticle supported acid catalysts for organic transformations. The third case presents novel polymer brush supported Cobalt-salen catalysts for the enantioselective, hydrolytic kinetic resolution of epoxides. A fourth case presents novel, magnetic polymer brush supported organic and organometallic catalysts for organic transformations. The fifth example illustrates polymer and silica supported ruthenium-salen catalysts for the asymmetric cyclopropanation of olefins. The overall goal of this thesis work is to develop novel supports and immobilization techniques to advance the field of hybrid organic/inorganic catalysts for the production of fine chemical and pharmaceutical intermediates.

Stable dinuclear complexes bis(heptane-2,4,6-trionato)dicopper(II) [Cu2(daa)2], bis(1,5-diphenyl-1,3,5-pentanetrionato)dicopper(II) [Cu2(dba)2], bis(1,5-diphenyl-1,3,5-pentanetrionato)dicobalt(II) [Co2(dba)2], and [6,11-dimethyl-7,10-diazahexadeca-5,11-diene-2,4,13,15-tetranato(4-)-N7N10O4O13;O2O4O13O15] copper(II)cobalt(II) [(CuCo(daaen)] were supported on Cab-O-Sil by the batch impregnation technique. The supported samples were characterized by UV-Vis, elemental analysis, X-ray powder diffraction (XRD), diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS), and thermal gravimetric analysis (TGA). Elemental analysis and TGA data confirm that the Cu2(daa)2 complex loses one of its coordinated ligands upon adsorption onto silica in THF at greater than 4.43 wt% Cu loading. By contrast, at all Cu loadings the Cu2(dba)2 complex was adsorbed on the silica surface in CH2Cl2 without loss of ligand. XRD and DRIFTS results confirmed the formation of Cu2(dba)2 multilayer films on the Cab-O-Sil surface for samples containing greater than 2.64 wt% copper. The dinuclear cobalt complex and copper-cobalt complex also do not lose their coordination ligands upon adsorption on the surface. These two metal complexes are amorphous and did not produce XRD patterns. However, DRIFTS results confirm that the binuclear cobalt complex and the copper-cobalt complex begin forming multilayer films between 1.21and 2.53 wt% Cu. The Cu2(dba)2/silica precatalysts were subsequently converted to the catalysts by decomposing the organic ligands at 450 degrees Celsius followed by activation with 2% H2 at 250 degrees Celsius and were evaluated for methanol synthesis and methanol decomposition reactions. Kinetic studies demonstrated that the 3.70% Cu/silica[Cu2(dba)2] catalyst is more active for methanol decomposition than it is for methanol synthesis. The supported dinuclear cobalt and copper-cobalt precatalysts were converted to the catalyst by heating at 450 degrees Celsius followed by activation of the catalysts with 50% H2. Four different catalysts, 3.5% Co/silica[Co2(dba)2], 6.7% Co/silica[Co2(dba)2], 2.3% Co/silica[CuCo(daaen)], and 5.5% Co/silica[Co2(daa)2] were evaluated for the Fischer-Tropsch reaction at 350 degrees Celsius in a batch reactor. The supported binuclear cobalt catalyst produced C1-C7 alkanes and a significant amount of CO2. By contrast, the catalyst formed from heterobinuclear CuCo(daaen) showed the ability to convert syngas to aromatics with a narrow product distribution. In addition, the 6.7% Co/silica[Co2(dba)2] multilayer catalysts have above 98% conversion rates and 60% liquid hydrocarbon selectivity in a flow reactor.

La préparation par voie Chimie Organométallique de Surface de nouveaux catalyseurs à base de hafnium supportés sur l’γ-alumine déshydroxylée à 500°C, γ-Al2O3-(500°C), a été réalisée dans ce travail de thèse. La combinaison de résultats chimiques (bilan matière, analyses élémentaires, marquage isotopique, thermolyse, réactions d’hydrogénolyse, d’oxydation, et réactions en réacteur continu), spectroscopiques (IR, RMN 1D, 2D), et des modélisation DFT ont abouti à la caractérisation et à la quantification des cinq produits majoritaires lors de la réaction de [Hf(CH2tBu)4] avec γ-Al2O3-(500°C) : un complexe monopodale (2), [(≡AlIVO) Hf(CH2tBu)3] (40%), un complexe bipodale dans deux environnements différents (4a and 4b), [(AlsO)(≡AlIVO)Hf(CH2tBu)2], (26%) et deux complexes cationiques (5 and 6) [(≡AlIVO)(AlsO)(Al-O-Al)]Hf(CH2tBu)] + [tBuCH2Als]- (Als correspond à un aluminium de surface Al III ou un AlV ) ( 34%). L’hydrogénolyse de ces complexes conduit à la formation majoritaire à 150°C de complexes monohydrures de hafnium du type :[(AlsO)3Hf-H], (70-80%) et [(≡AlIVO)(AlsO)Hf-H]+[(CH2tBu)Als]- (20-30%) caractérisés et quantifiés par la même approche expérience-théorie. Tous ces complexes sont actifs en polymérisation des α-oléfines (éthylène, propylène, isobutylène) et en copolymérisation éthylène-isobutylène. L’étude de ces réactions catalytiques a nécessité l’adaptation et la mise au point d’un réacteur en phase gaz spécifique appelé « Gas stopped flow polymérization » / New well-defined hafnium alkyl and hydrid complexes supported on γ-alumina dehydroxylatedt at 500°C, γ-Al2O3-(500°C), have been prepared. The structure of the surface complexes obtained by grafting Hf(CH2tBu)4, 1, on γ-alumina has been resolved by a combined experimental (mass balance analysis, labeling, in situ IR, NMR) and theoretical (DFT calculations) study. Thermolysis, oxidation and hydrogenolysis reactions have unambiguously proved the presence of two kinds of neopentyl-metal bonds: Hf-CH2tBu and Al-CH2tBu. Three coexisting surface complexes have been fully characterized and quantified: a monoaluminoxy- [(≡AlIVO)Hf(CH2tBu)3], a neutral bisaluminoxy [(≡AlIVO)(AlsO)Hf(CH2tBu)2], and a zwitterionic bisaluminoxy complex [(≡AlIVO) (AlsO)Hf(CH2tBu)2]+[(CH2tBu)Als]- in 40 %, 26 %, and 34 %, respectively. Hydrogenolysis reaction of these complexes leads to the formation at 150°C of [(AlsO)3HfH], (70-80%) and [(≡AlIVO)(AlsO)Hf(H)]+[(CH2tBu)Als]- (20-30%). All these hafnium alkyl and hydrides are active in α-olefin polymerization in absence of a co-catalyst