Spheroidal catalyst for olefin polymerization

Patent metadata

Field	Value
Publication number	US-10072111-B2
Application number	US-201815876532-A
Country	US
Kind code	B2
Filing date	Jan 22, 2018
Priority date	Dec 15, 2014
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

A solid, spheroidal polymerization catalyst having a particle size distribution characterized by a Dm*/Dn of less than 3.0, the catalyst comprising a phosphinimine catalyst, a cocatalyst and a magnesium chloride support. A process for the polymerization of ethylene with one or more alpha olefin catalyzed by a solid, spheroidal polymerization catalyst having a particle size distribution characterized by a Dm*/Dn of less than 3.0, the catalyst comprising a phosphinimine catalyst, a cocatalyst and a magnesium chloride support.

First claim

The invention claimed is:

1. A method of making a spheroidal olefin polymerization catalyst having a particle size distribution characterized by a Dm*/Dn of less than 3.0, wherein said method comprises:
i) combining a dialkylmagnesium compound with a non-protic ether,
ii) combining the product of step i) with a source of chloride anion,
iii) treating the product of step ii) to substantially remove to provide a MgCl 2 support containing less than about 2.5 wt. % of the non-protic ether,
iv) combining the product of step iii) with a phosphinimine catalyst and a cocatalyst.

2. The method of claim 1 wherein treating the product of step ii) to remove the non-protic ether comprises heating the product of step ii).

3. The method of claim 1 wherein treating the product of step ii) to remove the non-protic ether comprises adding an alkylaluminumchloride compound.

4. The method of claim 1 wherein the phosphinimine catalyst has the formula: (L)(PI)MX 2 , where M is Ti, Zr or Hf; PI is a phosphinimine ligand having the formula R 3 P═N—, where R is independently selected from the group consisting of hydrogen, halogen, and C 1 -C 20 hydrocarbyl; L is a ligand selected from the group consisting of cyclopentadienyl, substituted cyclopentadienyl, indenyl, substituted indenyl, fluorenyl, and substituted fluorenyl; and X is an activatable ligand.

5. The method of claim 1 wherein the phosphinimine catalyst has the formula: (L)((t-Bu) 3 P═N)TiX 2 , where L is a cyclopentadienyl ligand, a substituted cyclopentadienyl ligand, an indenyl ligand, or a substituted indenyl ligand; and X is an activatable ligand.

6. The method of claim 1 wherein the phosphinimine catalyst has the formula: (L)((t-Bu) 3 P═N)TiX 2 , where L is a substituted cyclopentadienyl ligand, or a substituted indenyl ligand; and X is an activatable ligand.

7. The method of claim 1 wherein the cocatalyst is selected from the group consisting of ionic activators, alkylaluminoxanes and mixtures thereof.

Assignees

• Nova Chem Int Sa

Inventors

• Wang Qinyan
• Craig Tyler
• Kondage Savina Udara Suduweli
• Funk Bradley Wade

Classifications

• C08F4/649

  organic · CPC title

• C08F4/65916

  supported on a carrier, e.g. silica, MgCl2, polymer · CPC title

• C08F4/022

  Magnesium halide as support anhydrous or hydrated or complexed by means of a Lewis base for Ziegler-type catalysts · CPC title

• C08F210/16 Primary

  Copolymers of ethene with alpha-alkenes, e.g. EP rubbers · CPC title

• C08F2420/04

  Cp or analog not bridged to a non-Cp X ancillary anionic donor · CPC title