Discovery and Development of Pyridine-bis(imine) and Related Catalysts for Olefin Polymerization and Oligomerization

For over 40 years following the polyolefin catalyst discoveries of Hogan and Banks (Phillips) and Ziegler (Max Planck Institute), chemists traversed the periodic table searching for new transition metal and lanthanide-based olefin polymerization systems. Remarkably, none of these "hits" employed iron, that is, until three groups independently reported iron catalysts for olefin polymerization in the late 1990's. The history surrounding the discovery of these catalysts was only the beginning of their uniqueness, as the ensuing years have proven these systems remarkable in several regards. Of primary importance are the pyridine-bis(imine) ligands (herein referred to as PDI), which produced iron catalysts that are among the world's most active for ethylene polymerization, demonstrated "staying power" despite over 15 years of ligand improvement efforts, and generated highly active polymerization systems with cobalt, chromium, and vanadium. Although many ligands have been employed in iron-catalyzed polymerization, the PDI family has thus far provided the most information about iron's capabilities and tendencies. For example, iron systems tend to be highly selective for ethylene over higher olefins, making them strong candidates for producing highly crystalline polyethylene, or highly linear α-olefins. Iron PDI polymerizes propylene with 2,1-regiochemistry via a predominantly isotactic, chain end control mechanism. Because the first insertion proceeds via 1,2-regiochemistry, iron (and cobalt) PDI systems can be tailored to make highly linear dimers of α-olefins by "head-to-head" coupling, resulting from a switch in regiochemistry after the first insertion. Finally, PDI ligands, while not being surpassed in activity, have inspired the development of related ligand families and complexes, such as pendant donor diimines (PDD), which are also highly efficient at producing linear α-olefins. This Account will detail a variety of oligomerization and polymerization results achieved with PDI and PDD catalysts. Our studies on ligand modification are discussed, but numerous ligands have been synthesized by others. Computational approaches, identification of catalyst active sites, noninnocent ligand studies, commercialization efforts, and other outstanding research are only briefly mentioned, at most. The reader is directed to review articles where appropriate, in order to address the cursory treatment of these areas.