Olefin polymerization catalyst components and process for the production of olefin polymers therewith

Patent metadata

Field	Value
Publication number	US-10124324-B1
Application number	US-201715590559-A
Country	US
Kind code	B1
Filing date	May 9, 2017
Priority date	May 9, 2017
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

The present invention relates to a Ziegler-Natta catalyst component for olefin polymerization containing an amide element in combination with one or more internal electron donors. The catalyst components, according to the present invention, are able to produce polypropylene polymers with higher stereo-regularity. The present invention also provides a phthalate-free catalyst system capable of producing polypropylene with an isotacticity that is equal to or higher than catalyst systems containing phthalate derivatives.

First claim

What is claimed is:

1. A solid catalyst component for the polymerization or co-polymerization of alpha-olefins comprising: titanium, magnesium, halogen, one or more internal electron donors, and one or more amide compounds selected from the compound represented by the formula:

wherein R is an aliphatic hydrocarbon having 1 to 20 carbon atoms and contains a carbonyl or carbonyl ester group;
wherein R 1 is alkyl group having 1 to 20 carbon atoms; and
wherein R 2 is hydrogen, alkyl group having 1 to 20 carbon atom, phenyl, carbonyl or alkoxy carbonyl.

2. The component of claim 1 , wherein the one or more amide compounds are selected from cyclic amide compounds, wherein two or more of R, R 1 , and R 2 are linked to form one or more saturated or unsaturated monocyclic or polycyclic rings.

3. The component of claim 1 , wherein the one or more amide compounds are non-cyclic amide compounds.

4. The component of claim 1 , wherein the one or more amide compounds are selected from 3-ethoxycarbonyl-2-piperidone, n-methyl-2-piperidone, 2-piperidone, 2-pyrrolidinone, n-tert-butoxycarbonyl-2-piperidone, n-methyl-2-pyridone, 1-cyclohexyl-2-pyrrolidone, 1-benzyl-2-piperidone, 1-phenyl-2-pyrrolidinone, n,n-dimethylpropionamide, n,n-dimethylisobutyramide, n,n-dimethylacetamide, n,n-dimethylpentanamide, n,n-dimethylhexanamide, and their derivatives.

5. The component of claim 1 , wherein at least one of the one or more internal electron donors is selected from a 1,3 diether compound.

6. The component of claim 5 , wherein the 1,3 diether compound is selected from 9,9-bis(methoxymethyl)fluorene; 9,9-bis(methoxymethyl)-2,3,6,7-tetramethylfluorene; 9,9-bis(methoxymethyl)-2,3,4,5,6,7-hexafluorofluorene; 9,9-bis(methoxymethyl)-2,3-benzofluorene; 9,9-bis(methoxymethyl)-2,3,6,7-dibenzofluorene; 9,9-bis(methoxymethyl)-2,7-diisopropylfluorene; 9,9-bis(methoxymethyl)-1,8-dichlorofluorene; 9,9-bis(methoxymethyl)-2,7-dicyclopentylfluorene; 9,9-bis(methoxymethyl)-1,8-difluorofluorene; 9,9-bis(methoxymethyl)-1,2,3,4-tetrahydrofluorene; 9,9-bis(methoxymethyl)-1,2,3,4,5,6,7,8-octahydrofluorene; and 9,9-bis(methoxymethyl)-4-tert-butylfluorene.

7. The component of claim 5 , wherein the 1,3 diether compound is selected from 2-(2-ethylhexyl)-1,3-dimethoxypropane, 2-isopropyl-1,3-dimethoxypropane, 2-butyl-1,3-dimethoxypropane, 2-sec-butyl-1,3-dimethoxypropane, 2-cyclohexyl-1,3-dimethoxypropane, 2-phenyl-1,3-diethoxypropane, 2-cumyl-1,3-diethoxypropane, 2-(2-phenylethyl)-1,3-dimethoxypropane, 2-(2-cyclohexylethyl)-1,3-dimethoxypropane, 2-(p-chlorophenyl)1,3-dimethoxypropane, 2-(diphenylmethyl)-1,3-dimethoxypropane, 2-(1-naphthyl)-1,3-dimethoxy propane, 2,2-fluorophenyl)-1,3-dimethoxypropane, 2-(1-decahydronaphthyl)-1,3-dimethoxypropane, 2-(p-t-butylphenyl)-1,3-dimethoxypropane, 2,2-dicyclohexyl-1,3-dimethoxypropane, 2-isopentyl-2-isopropyl-1,3-dimethoxypropane, 2,2-diisobutyl-1,3-dimethoxypropane; 2-isopropyl 2-isopentyl-1,3-dimethoxypropane; and 2,2-bis(cyclohexylmethyl)-1,3-dimethoxypropane.

8. The component of claim 1 , wherein at least one of the one or more internal electron donors is selected from esters of phthalic acid.

9. The component of claim 1 , wherein at least one of the one or more internal electron donors is selected from malonate compounds.

10. The component of claim 1 , wherein at least one of the one or more internal electron donors is selected from esters of succinic acid compounds.

11. The component of claim 1 , wherein at least of the one or more internal electron donors is selected from esters of diol compounds.

12. A catalyst system for the polymerization or co-polymerization of alpha-olefins comprising:
a) a solid catalyst component according to claim 1 ; and
b) a co-catalyst component comprising an organoaluminum compound represented by the general formula: R n AlQ 3-n , wherein R represents an alkyl group having 1 to 6 carbon atoms, Q represents a hydrogen or a halogen atom, and n represents a real number that satisfies 0<n≤3.

13. The catalyst system of claim 12 , further comprising: (c) one or more external electron donor components.

14. The catalyst system of claim 12 , wherein the one or more amide compounds of the solid catalyst component are selected from cyclic amide compounds, wherein two or more of R, R 1 , and R 2 are linked to form one or more saturated or unsaturated monocyclic or polycyclic rings.

15. The catalyst system of claim 12 , wherein the one or more amide compounds of the solid catalyst component are non-cyclic amide compounds.

16. The catalyst system of claim 12 , wherein at least one of the one or more internal electron donors of the solid catalyst component is selected from a 1,3 diether compound.

17. The catalyst system of claim 12 , wherein at least one of the one or more internal electron donors of the solid catalyst component is selected from esters of phthalic acid.

18. The catalyst system of claim 12 , wherein at least one of the one or more internal electron donors of the solid catalyst component is selected from malonate compounds.

19. The catalyst system of claim 12 , wherein at least one of the one or more internal electron donors of the solid catalyst component is selected from esters of succinic acid compounds.

20. The catalyst system of claim 12 , wherein at least one of the one or more internal electron donors of the solid catalyst component is selected from esters of diol compounds.

21. A solid catalyst component for the polymerization or co-polymerization of alpha-olefins comprising: titanium, magnesium, halogen, one or more internal electron donors, and one or more amide compounds selected from 3-ethoxycarbonyl-2-piperidone, n-methyl-2-piperidone, 2-piperidone, 2-pyrrolidinone, n-tert-butoxycarbonyl-2-piperidone, n-methyl-2-pyridone, 1-cyclohexyl-2-pyrrolidone, 1-benzyl-2-piperidone, 1-phenyl-2-pyrrolidinone, n,n-dimethylpropionamide, n,n-dimethylisobutyramide, n,n-dimethylacetamide, n,n-dimethylpentanamide, n,n-dimethylhexanamide, and their derivatives.

22. The component of claim 21 , wherein at least one of the one or more internal electron donors is selected from a 1,3 diether compound.

23. The component of claim 22 , wherein the 1,3 diether compound is selected from 9,9-bis(methoxymethyl)fluorene; 9,9-bis(methoxymethyl)-2,3,6,7-tetramethylfluorene; 9,9-bis(methoxymethyl)-2,3,4,5,6,7-hexafluorofluorene; 9,9-bis(methoxymethyl)-2,3-benzofluorene; 9,9-bis(methoxymethyl)-2,3,6,7-dibenzofluorene; 9,9-bis(methoxymethyl)-2,7-diisopropylfluorene; 9,9-bis(methoxymethyl)-1,8-dichlorofluorene; 9,9-bis(methoxymethyl)-2,7-dicyclopentylfluorene; 9,9-bis(methoxymethyl)-1,8-difluorofluorene; 9,9-bis(methoxymethyl)-1,2,3,4-tetrahydrofluorene; 9,9-bis(methoxymethyl)-1,2,3,4,5,6,7,8-octahydrofluorene; and 9,9-bis(methoxymethyl)-4-tert-butylfluorene.

24. The component of claim 22 , wherein the 1,3 diether compound is selected from 2-(2-ethylhexyl)-1,3-dimethoxypropane, 2-isopropyl-1,3-dimethoxypropane, 2-butyl-1,3-dimethoxypropane, 2-sec-butyl-1,3-dimethoxypropane, 2-cyclohexyl-1,3-dimethoxypropane, 2-phenyl-1,3-diethoxypropane, 2-cumyl-1,3-diethoxypropane, 2-(2-phenylethyl)-1,3-dimethoxypropane, 2-(2-cyclohexylethyl)-1,3-dimethoxypropane, 2-(p-chlorophenyl)1,3-dimethoxypropane, 2-(diphenylmethyl)-1,3-dimethoxypropane, 2-(1-naphthyl)-1,3-dimethoxy propane, 2,2-fluorophenyl)-1,3-dimethoxypropane, 2-(1-decahydronapht

Assignees

• Formosa Plastics Corp
• Formosa Plastics Corp Usa

Inventors

• Kong Gapgoung
• Zhang Lei
• Xu Demin
• Fang Yiqun
• Chen Chih-Jian

Classifications

• C08K2003/2217

  of magnesium · CPC title

• C08F110/06

  Propene · CPC title

• C08K3/22

  of metals · CPC title

• B01J37/009

  Preparation by separation, e.g. by filtration, decantation, screening · CPC title

• C08K3/08

  Metals · CPC title