Catalyst system for polymerization of an olefin

Patent metadata

Field	Value
Publication number	US-10000591-B2
Application number	US-201415106061-A
Country	US
Kind code	B2
Filing date	Dec 19, 2014
Priority date	Dec 20, 2013
Publication date	Jun 19, 2018
Grant date	Jun 19, 2018

Abstract

A process for the preparation of a catalyst system for olefin polymerization, including: A) providing said procatalyst obtainable via a process comprising: i) contacting a compound R 4 z MgX 4 2-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, ii) optionally contacting the solid product obtained in step i) with at least one activating compound selected from an activating electron donor or metal alkoxide compound; iii) contacting the first or second intermediate reaction product, with a halogen-containing Ti-compound and optionally an internal electron donor to obtain the procatalyst; and B) contacting the procatalyst with a co-catalyst and at least diethylaminotriethoxysilane as the external donor. Further disclosed is a catalyst system obtained by the process; a process for preparing a polyolefin by contacting at least one olefin with the catalyst system; a polyolefin obtained thereby; a composition comprising a propylene-ethylene copolymer; a shaped article thereof; and use of the polyolefin.

First claim

The invention claimed is:

1. A process for the preparation of a catalyst system suitable for olefin polymerization, wherein the process comprises:
A) providing a procatalyst obtained via a process comprising:
i) contacting a compound R 4 z MgX 4 2-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, being a solid Mg(OR 1 ) x X 1 2-x , wherein: R 4 is the same as R 1 being a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl or alkylaryl groups, and one or more combinations thereof; wherein said hydrocarbyl group is substituted or unsubstituted, optionally comprises one or more heteroatoms and has between 1 and 20 carbon atoms; X 4 and X 1 are each independently selected from fluoride (F − ), chloride (Cl − ), bromide (Br − ) or iodide (I − ); and z is in a range of larger than 0 and smaller than 2, being 0<z<2;
ii) optionally contacting the solid Mg(OR 1 ) x X 2-x obtained in step i) with at least one activating compound selected from activating electron donors and metal alkoxide compounds of formula M 1 (OR 2 ) v-w (OR 3 ) w or M 2 (OR 2 ) v-w (R 3 ) w , to obtain a second intermediate product; wherein M 1 is a metal selected from Ti, Zr, Hf, Al or Si; M 2 is a metal being Si; v is the valency of M 1 or M 2 , w is smaller than v; R 2 and R 3 are each a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof; wherein said hydrocarbyl group is substituted or unsubstituted, optionally contains one or more heteroatoms, and has between 1 and 20 carbon atoms;
iii) contacting the first or second intermediate reaction product, obtained respectively in step i) or ii), with a halogen-containing Ti-compound, an internal electron donor, and optionally, an activator to obtain said procatalyst; and

B) contacting said procatalyst with a co-catalyst and the at least one external electron donor that is diethylaminotriethoxysilane,
wherein the internal electron donor is an aminobenzoate according to formula XI

wherein R 80 , R 81 , R 82 , R 83 , R 84 , R 85 , and R 86 are independently selected from a group consisting of hydrogen, C 1 -C 10 straight and branched alkyl; C 3 -C 10 cycloalkyl; C 6 -C 10 aryl; and C 7 -C 10 alkaryl and aralkyl group;
wherein when one of R 83 and R 84 and one of R 85 and R 86 has at least one carbon atom, then the other one of R 83 and R 84 and of R 85 and R 86 is each a hydrogen atom;
wherein R 87 is selected from hydrogen, methyl, ethyl, propyl, isopropyl, butyl, t-butyl, phenyl, benzyl, substituted benzyl and halophenyl groups; and
wherein R 88 is selected from the group consisting of C 6 -C 10 aryl; and C 7 -C 10 alkaryl and aralkyl groups.

2. The process according to claim 1 , wherein the process is essentially phthalate free.

3. The process according to claim 1 , wherein
R 83 , R 84 , R 85 and R 86 are independently selected from C 1 -C 10 straight and branched alkyl and phenyl; and
R 88 is a substituted or unsubstituted phenyl, benzyl, naphthyl, ortho-tolyl, para-tolyl or anisol group.

4. The process according to claim 3 , wherein
R 83 , R 84 , R 85 and R 86 are independently selected from methyl, ethyl, propyl, isopropyl, butyl, t-butyl, and phenyl groups; and
R 88 is phenyl.

5. The process according to claim 1 , wherein the internal electron donor is selected from 4-[benzoyl(methyl)amino]pentan-2-yl benzoate; 2,2,6,6-tetramethyl-5-(methylamino)heptan-3-ol dibenzoate; 4-[benzoyl (ethyl)amino]pentan-2-yl benzoate, 4-(methylamino)pentan-2-yl bis(4-methoxy)benzoate), 3-[benzoyl(cyclohexyl)amino]-1-phenylbutyl benzoate, 3-[benzoyl(propan-2-yl)amino]-1-phenylbutyl, 4-[benzoyl(methyl)amino]-1,1,1-trifluoropentan-2-yl, 3-(methylamino)-1,3-diphenylpropan-1-ol dibenzoate, 3-(methyl)amino-propan-1-ol dibenzoate; 3-(methyl)amino-2,2-dimethylpropan-1-ol dibenzoate, and 4-(methylamino)pentan-2-yl bis(4-methoxy)benzoate).

6. The process according to claim 1 , wherein the activator is present and is added prior to or simultaneously with the addition to the internal electron donor.

7. The process according to claim 6 , wherein the activator is a benzamide according to formula X

wherein:
R 70 and R 71 are each independently selected from hydrogen or an alkyl; and
R 72 , R 73 , R 74 , R 75 , R 76 are each independently selected from hydrogen, a heteroatom such as a halide, or a hydrocarbyl group selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof.

8. The process according to claim 7 , wherein R 70 and R 71 are each independently selected from hydrogen and an alkyl having between 1 and 6 carbon atoms.

9. The process according to claim 8 wherein the activator is N, N-dimethylbenzamide.

10. The process according to claim 7 , wherein the benzamide according to formula X is present in the procatalyst in an amount from 0.1 to 4 wt. % as determined using HPLC.

11. A catalyst system obtained by the process of claim 1 .

12. A process for preparing a polyolefin, comprising contacting at least one olefin with the catalyst system according to claim 11 .

13. The process according to claim 12 , wherein the olefin is propylene or a combination of propylene and ethylene.

14. The process of claim 1 , wherein
the activator is present and is added prior to or simultaneously with the addition to the internal electron donor,
wherein the activator is a benzamide according to formula X

wherein:
R 70 and R 71 are each independently selected from hydrogen or an alkyl; and
R 72 , R 73 , R 74 , R 75 , R 76 are each independently selected from hydrogen, a heteroatom such as a halide, or a hydrocarbyl group selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof; and
wherein the benzamide according to formula X is present in the procatalyst in an amount from 0.1 to 3 wt. % as determined using HPLC.

15. The process of claim 14 , wherein
the internal electron donor is selected from 4-[benzoyl(methyl)amino]pentan-2-yl benzoate; 2,2,6,6-tetramethyl-5-(methylamino)heptan-3-ol dibenzoate; 4-[benzoyl (ethyl)amino]pentan-2-yl benzoate, 4-(methylamino)pentan-2-yl bis(4-methoxy)benzoate), 3-[benzoyl(cyclohexyl)amino]-1-phenylbutyl benzoate, 3-[benzoyl(propan-2-yl)amino]-1-phenylbutyl, 4-[benzoyl(methyl)amino]-1,1,1-trifluoropentan-2-yl, 3-(methylamino)-1,3-diphenylpropan-1-ol dibenzoate, 3-(methyl)amino-propan-1-ol dibenzoate; 3-(methyl)amino-2,2-dimethylpropan-1-ol dibenzoate, and 4-(methylamino)pentan-2-yl bis(4-methoxy)benzoate); and
the activator is N, N-dimethylbenzamide, and is present in the procatalyst an amount from 0.1 to 1.5 wt. % as determined using HPLC.

16. A catalyst system obtained by the process of claim 14 .

17. A process for preparing a polypropylene or a propylene-ethylene copolymer, comprising contacting propylene or a combination of propylene and ethylene with the catalyst system according to claim 15 .

Assignees

• Saudi Basic Ind Corp
• Sabic Global Technologies Bv

Inventors

• Batinas-Geurts Aurora Alexandra
• Zuideveld Martin Alexander
• Gerlofsma Raymond
• Steenbakkers-Menting Henrica Norberta Alberta Maria
• Degenhart Peter

Classifications

• C08L2207/02

  Heterophasic composition · CPC title

• C08F4/6565

  and magnesium or compounds thereof · CPC title

• C08F4/651

  Pretreating with non-metals or metal-free compounds · CPC title

• C08F210/06 Primary

  Propene · CPC title

• C08F4/6465

  containing silicium · CPC title