Selective Dimerization of Ethylene to 1-Butene with a Porous Catalyst

Current heterogeneous catalysts lack the fine steric and electronic tuning required for catalyzing the selective dimerization of ethylene to 1-butene, which remains one of the largest industrial processes still catalyzed by homogeneous catalysts. Here, we report that a metal–organic framework catalyzes ethylene dimerization with a combination of activity and selectivity for 1-butene that is premier among heterogeneous catalysts. The capacity for mild cation exchange in the material MFU-4l (MFU-4l = Zn[subscript 5]Cl[subscript 4](BTDD)[subscript 3], H[subscript 2]BTDD = bis(1H-1,2,3-triazolo[4,5-b],[4′,5′-i])dibenzo[1,4]dioxin) was leveraged to create a well-defined and site-isolated Ni(II) active site bearing close structural homology to molecular tris-pyrazolylborate complexes. In the presence of ethylene and methylaluminoxane, the material consumes ethylene at a rate of 41,500 mol per mole of Ni per hour with a selectivity for 1-butene of up to 96.2%, exceeding the selectivity reported for the current industrial dimerization process.Saudi AramcoAmerican Society for Engineering Education. National Defense Science and Engineering Graduate Fellowship3M CompanyResearch Corporation for Science Advancement. Cottrell Scholars ProgramAlfred P. Sloan Foundatio

Mechanism of Single-Site Molecule-Like Catalytic Ethylene Dimerization in Ni-MFU‑4<i>l</i>

A recently developed metal–organic framework (MOF) catalyst for the dimerization of ethylene has a combination of selectivity and activity that surpasses that of commercial homogeneous catalysts, which have dominated this important industrial process for nearly 50 years. The uniform catalytic sites available in MOFs provide a unique opportunity to directly study reaction mechanisms in heterogeneous catalysts, a problem typically intractable due to the multiplicity of coordination environments found in many solid catalysts. In this work, we use a combination of isotopic labeling studies, mechanistic probes, and DFT calculations to demonstrate that Ni-MFU-4<i>l</i> operates via the Cossee-Arlman mechanism, which has also been implicated in homogeneous late transition metal catalysts. These studies demonstrate that metal nodes in MOFs mimic homogeneous catalysts not just functionally, but also mechanistically. They provide a blueprint for the development of advanced heterogeneous catalysts with similar degrees of tunability to their homogeneous counterparts

Mechanism of Single-Site Molecule-Like Catalytic Ethylene Dimerization in Ni-MFU‑4<i>l</i>

A recently developed metal–organic framework (MOF) catalyst for the dimerization of ethylene has a combination of selectivity and activity that surpasses that of commercial homogeneous catalysts, which have dominated this important industrial process for nearly 50 years. The uniform catalytic sites available in MOFs provide a unique opportunity to directly study reaction mechanisms in heterogeneous catalysts, a problem typically intractable due to the multiplicity of coordination environments found in many solid catalysts. In this work, we use a combination of isotopic labeling studies, mechanistic probes, and DFT calculations to demonstrate that Ni-MFU-4<i>l</i> operates via the Cossee-Arlman mechanism, which has also been implicated in homogeneous late transition metal catalysts. These studies demonstrate that metal nodes in MOFs mimic homogeneous catalysts not just functionally, but also mechanistically. They provide a blueprint for the development of advanced heterogeneous catalysts with similar degrees of tunability to their homogeneous counterparts

Single-Site Heterogeneous Catalysts for Olefin Polymerization Enabled by Cation Exchange in a Metal-Organic Framework

The manufacture of advanced polyolefins has been critically enabled by the development of single-site heterogeneous catalysts. Metal-organic frameworks (MOFs) show great potential as heterogeneous catalysts that may be designed and tuned on the molecular level. In this work, exchange of zinc ions in Zn₅Cl₄(BTDD)₃, H₂BTDD = bis­(1<i>H</i>-1,2,3-triazolo­[4,5-<i>b</i>],[4′,5′-i])­dibenzo­[1,4]­dioxin) (MFU-4<i>l</i>) with reactive metals serves to establish a general platform for selective olefin polymerization in a high surface area solid promising for industrial catalysis. Characterization of polyethylene produced by these materials demonstrates both molecular and morphological control. Notably, reactivity approaches single-site catalysis, as evidenced by low polydispersity indices, and good molecular weight control. We further show that these new catalysts copolymerize ethylene and propylene. Uniform growth of the polymer around the catalyst particles provides a mechanism for controlling the polymer morphology, a relevant metric for continuous flow processes

Highly Selective Heterogeneous Ethylene Dimerization with a Scalable and Chemically Robust MOF Catalyst

Metal-organic frameworks (MOFs) hold great promise as structurally tunable catalysts capable of high selectivity in the solid state, yet their comparatively high cost and often limited stability remain significant concerns for their commercialization as heterogeneous catalysts. Here, we report detailed X-ray absorption spectroscopy studies of Co- and Ni-MFU-4l, a class of highly selective MOF catalysts for olefin upgrading, and reveal mechanisms that lead to their deactivation. We further show that Ni-CFA-1, a more scalable and economical alternative to Ni-MFU-4l, reproduces both the local coordination structure and the high selectivity of the latter in ethylene dimerization catalysis. Under optimal conditions, Ni-CFA-1 activated by MMAO-12 achieves a turnover frequency of 37100 per hour and a selectivity of 87.1% for 1-butene, a combination of activity, selectivity, and affordability that is unmatched among heterogeneous ethylene dimerization catalysts. Ni-CFA-1 retains its high activity for at least 12 h in a one-liter semibatch reactor, offering a strategy toward robust and scalable MOFs for industrial catalysis

Structural Evolution of MOF-Derived RuCo, A General Catalyst for the Guerbet Reaction

Guerbet alcohols, a class of β-branched terminal alcohols, find widespread application because of their low melting points and excellent fluidity. Because of the limitations in the activity and selectivity of existing Guerbet catalysts, Guerbet alcohols are not currently produced via the Guerbet reaction but via hydroformylation of oil-derived alkenes followed by aldol condensation. In pursuit of a one-step synthesis of Guerbet alcohols from simple linear alcohol precursors, we show that MOF-derived RuCo alloys achieve over a million turnovers in the Guerbet reaction of 1-propanol, 1-butanol, and 1-pentanol. The active catalyst is formed in situ from ruthenium-impregnated metal-organic framework MFU-1. XPS and XAS studies indicate that the precatalyst is composed of Ru precursor trapped inside the MOF pores with no change in the oxidation state or coordination environment of Ru upon MOF incorporation. The significantly higher reactivity of Ru-impregnated MOF versus a physical mixture of Ru precursor and MOF suggests that the MOF plays an important role in templating the formation of the active catalyst and/or its stabilization. XPS reveals partial reduction of both ruthenium and MOF-derived cobalt under the Guerbet reaction conditions, and TEM/EDX imaging shows that Ru is decorated on the edges of dense nanoparticles, as well as thin nanoplates of CoOx. The use of ethanol rather than higher alcohols as a substrate results in lower turnover frequencies, and RuCo recovered from ethanol upgrading lacks nanostructures with plate-like morphology and does not exhibit Ru-enrichment on the surface and edge sites. Notably, 1H and 31P NMR studies show that through use of K3PO4 as a base promoter in the RuCo-catalyzed alcohol upgrading, the formation of carboxylate salts, a common side product in the Guerbet reaction, was effectively eliminated

Highly Stereoselective Heterogeneous Diene Polymerization by Co-MFU-4

Molecular catalysts offer tremendous advantages for stereoselective polymerization because their activity and selectivity can be optimized and understood mechanistically using the familiar tools of organometallic chemistry. Yet, this exquisite control over selectivity comes at an operational price that is generally not justifiable for the large-scale manufacture of polyfolefins. In this report, we identify Co-MFU-4l, prepared by cation exchange in a metal–organic framework, as a solid catalyst for the polymerization of 1,3-butadiene with high stereoselectivity (>99% 1,4-cis). To our knowledge, this is the highest stereoselectivity achieved with a heterogeneous catalyst for this transformation. The polymer’s low polydispersity (PDI ≈ 2) and the catalyst’s ready recovery and low leaching indicate that our material is a structurally resilient single-site heterogeneous catalyst. Further characterization of Co-MFU-4l by X-ray absorption spectroscopy provided evidence for discrete, tris-pyrazolylborate-like coordination of Co(II). With this information, we identify a soluble cobalt complex that mimics the structure and reactivity of Co-MFU-4l, thus providing a well-defined platform for studying the catalytic mechanism in the solution phase. This work underscores the capacity for small molecule-like tunability and mechanistic tractability available to transition metal catalysis in metal–organic frameworks.National Science Foundation (U.S.) (Grant DMR-1452612

Stabilized Vanadium Catalyst for Olefin Polymerization by Site Isolation in a Metal-Organic Framework

Vanadium catalysts offer unique selectivity in olefin polymerization, yet are underutilized industrially owing to their poor stability and productivity. Reported here is the immobilization of vanadium by cation exchange in MFU-4l, thus providing a metal–organic framework (MOF) with vanadium in a molecule-like coordination environment. This material forms a single-site heterogeneous catalyst with methylaluminoxane and provides polyethylene with low polydispersity (PDI≈3) and the highest activity (up to 148 000 h−1) reported for a MOF-based polymerization catalyst. Furthermore, polyethylene is obtained as a free-flowing powder as desired industrially. Finally, the catalyst shows good structural integrity and retains polymerization activity for over 24 hours, both promising attributes for the commercialization of vanadium-based polyolefins.National Science Foundation (grant no. DMR-1452612

Selective Dimerization of Propylene with Ni-MFU‑4<i>l</i>

We report the selective dimerization of propylene to branched hexenes using Ni-MFU-4<i>l</i>, a solid catalyst prepared by cation exchange. Analysis of the resulting product distribution demonstrates that the selectivity arises from 2,1-insertion and slow product reinsertion, mechanistic features reproduced by a molecular nickel tris-pyrazolylborate catalyst. Characterization of Ni-MFU-4<i>l</i> by X-ray absorption spectroscopy provides evidence for discrete, tris-pyrazolylborate-like coordination of nickel, underscoring the small-molecule analogy that can be made at metal–organic framework nodes

Gas Phase Ethylene Polymerization by Single-Site Cr Centers in a MetalOrganic Framework

We report a systematic study on the gas-phase polymerization of ethylene by a metal–organic framework (MOF) catalyst. Cr3+-exchanged MFU-4l (Cr(III)-MFU-4l, MFU-4l = Zn5Cl4(BTDD)3, H2BTDD = bis(1H-1,2,3,-triazolo[4,5-b],[4′,5′-i])dibenzo[1,4]dioxin)) serves as an exemplary system to demonstrate prereaction treatment with alkylaluminum species as a simple method to isolate an active MOF catalyst for liquid-free polymerization of ethylene. AlMe3-treated Cr(III)-MFU-4l subjected to 40 bar of ethylene exhibits a polymerization activity of 52 000 molEthylene·molCr–1·h–1, an order of magnitude higher than that observed in a slurry-phase reaction with Cr(III)-MFU-4l and excess alkylaluminum species. Furthermore, product polyethylene exhibits a low polydispersity index of 1.36 and a free-flowing granular morphology favorable for industrial processing, highlighting the advantages conferred by the single-site MOF catalysts in gas-phase ethylene polymerization. Keywords:metal−organic framework; heterogeneous catalysis; single-site catalyst; polyethylene; gas-phase polymerizationOffice of Basic Energy Sciences (grant no. DE-SC0016214)National Science Foundation CAREER (grant no. DMR-1452612