Ziegler-natta catalysts doped with non-Group IV metal chlorides

Patent metadata

Field	Value
Publication number	US-10294311-B2
Application number	US-201815918075-A
Country	US
Kind code	B2
Filing date	Mar 12, 2018
Priority date	Feb 16, 2011
Publication date	May 21, 2019
Grant date	May 21, 2019

Abstract

A process may include contacting ethylene monomer with Ziegler-Natta catalyst to form polyethylene. The Ziegler-Natta catalyst may be formed by contacting an alkyl magnesium compound with an alcohol and a metal reagent to form a blend, and contacting the blend with a first agent to form a solution of reaction product “A”. The solution of reaction product “A” may be contacted with a second agent to form a solid reaction product “B”, and the solid reaction product “B” may be contacted with a third agent to form a solid reaction product “C”. The solid reaction product “C” may be contacted with a fourth agent to form a solid reaction product “D”, and the solid reaction product “D” may be contacted with a fifth agent to form a catalyst component.

First claim

What is claimed is:

1. A polymerization process comprising:
providing ethylene monomer;
contacting the ethylene monomer with a Ziegler-Natta catalyst within a polymerization reactor under conditions sufficient to form polyethylene; and
recovering polyethylene from the polymerization reactor, wherein a shear response and activity for the polyethylene is greater than a shear response and activity for an identically formed polyethylene absent the metal reagent in the Ziegler-Natta catalyst, and wherein the Ziegler-Natta catalyst is formed by a process comprising:
contacting an alkyl magnesium compound with an alcohol and a metal reagent to form a blend of a magnesium dialkoxide compound and a metal;
contacting the blend of the magnesium dialkoxide compound and the metal with a first agent to form a solution of reaction product “A”, the first agent comprising a halogenating/titanating agent;
contacting the solution of reaction product “A” with a second agent to form a solid reaction product “B”, the second agent comprising a blend of a first metal halide and a metal alkoxide;
contacting the solid reaction product “B” with a third agent to form a solid reaction product “C”, the third agent comprising a second metal halide;
contacting the solid reaction product “C” with a fourth agent to form a solid reaction product “D”, the fourth agent comprising a third metal halide; and
contacting the solid reaction product “D” with a fifth agent to form a catalyst component, the fifth agent comprising an organoaluminum compound;
wherein the metal in the metal reagent is selected from Cr 3+ , Fe 2+ , Mn 2+ , and Ba 2+ .

2. The process of claim 1 , wherein the polyethylene exhibits an SR2 of from about 30 to about 50.

3. The process of claim 1 , wherein the polyethylene exhibits a Mz/Mw of from about 4.0 to about 9.0.

4. The process of claim 1 , wherein the polymerization process exhibits an activity of from about 23,000 g/g/h to about 70,000 g/g/h.

5. Polyethylene formed by the process of claim 1 .

6. The process of claim 1 , wherein the blend of the first metal halide and the metal alkoxide is generally represented by the formula:
TiCl 4 /Ti(OR 5 ) 4
wherein R 5 is selected from C 2 to C 20 alkyl groups.

7. The process of claim 1 , wherein the blend of the first metal halide and the metal alkoxide is selected from a titanium tetrachloride/tetra n-butyl titanate (TiCl 4 /TNBT) blend, a titanium tetrachloride/titanium 2-ethylhexyl alkoxide blend and combinations thereof.

Assignees

• Fina Technology

Inventors

• Zhang Lei
• Knoeppel David

Classifications

• C08F2500/18

  Bulk density · CPC title

• C08F2500/07

  High density, i.e. > 0.95 g/cm3 · CPC title

• C08F4/6574

  and magnesium or compounds thereof · CPC title

• C08F2410/03

  Multinuclear procatalyst, i.e. containing two or more metals, being different or not · CPC title

• C08F2500/11

  Melt tension or melt strength · CPC title