Components and catalysts for the polymerization of olefins

Patent metadata

Field	Value
Publication number	US-11220519-B2
Application number	US-201917267601-A
Country	US
Kind code	B2
Filing date	Jul 25, 2019
Priority date	Aug 14, 2018
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

A solid catalyst component for the polymerization of olefins CH2═CHR in which R is hydrogen or a hydrocarbon radical with 1-12 carbon atoms, made from or containing Mg, Ti, Bi, halogen and an electron donor obtained from a process including the steps:(a) dissolving a Mg(OR)2 compound wherein R groups, equal to or different from each other, are C1-C15 hydrocarbon groups optionally containing a heteroatom selected from O, N and halogen, in an organic liquid medium, thereby forming a first liquid mixture;(b) contacting the first liquid mixture (a) with TiCl4, thereby forming a second liquid mixture absent a solid phase, and(c) subjecting the second liquid mixture (b) to conditions, whereby solid catalyst particles are formed,wherein (i) a Bi compound and (ii) a bidentate electron donor compound are present in one or more of steps (a) to (c) and/or contacted with the solid catalyst particles obtained from (c).

First claim

What is claimed is:

1. A solid catalyst component for the polymerization or copolymerization of olefins CH 2 =CHR wherein R is hydrogen or a hydrocarbon radical with 1-12 carbon atoms comprising titanium, magnesium, halogen, bismuth and an electron donor compound obtained by a process comprising the following steps:
(a) dissolving a Mg(OR) 2 compound wherein R groups, equal to or different from each other, are C 1 -C 15 hydrocarbon groups optionally containing a heteroatom selected from O, N and halogen, in an organic liquid medium, thereby forming a first liquid mixture;
(b) contacting the first liquid mixture of step (a) with TiCl 4 , thereby forming a second liquid mixture absent a solid phase, and
(c) subjecting the second liquid mixture of step (b) to conditions, whereby solid catalyst particles are formed,
wherein (i) a Bi compound and (ii) a bidentate electron donor compound are present in one or more of steps (a) to (c) and/or contacted with the solid catalyst particles obtained from step (c).

2. The catalyst component according to claim 1 , wherein the Bi compound is selected from the group consisting of Bi halides, Bi carbonate, Bi carboxylates, Bi nitrate, Bi oxide, Bi sulphate and Bi sulfide.

3. The catalyst component according to claim 2 , wherein the Bi compound is selected from the group consisting of Bi trichloride and a Bi decanoate.

4. The catalyst component according to claim 1 , wherein the Bi compound is used in an amount ranging from 0.005 to 0.2 mole per mole of Mg.

5. The catalyst component according to claim 1 , wherein the Mg(OR) 2 compound is a magnesium alkoxide wherein R is a C 1 -C 15 alkyl group or has the structure of an ether group —ROR wherein R is a C 1 -C 15 alkyl group as well.

6. The catalyst component according to claim 1 , wherein in step (b), the second liquid mixture is prepared by reacting the Mg alkoxide with TiCl 4 , a titanium alkoxide, a phenolic compound and an alkanol in an inert liquid diluent.

7. The catalyst component according to claim 6 , wherein the alkoxy groups of the Mg alkoxide, alkanol and those of the Ti alkoxides, independently have up to 4 carbon atoms inclusive.

8. The catalyst component according to claim 6 , wherein the reaction step (b) is carried out according to the following scheme carried out at a temperature ranging from 30 to 120° C.:
3Mg(OEt) 2 +x Ti(OEt) 4 +y TiCl 4 +z o -cresol+ n EtOH.
wherein y is more than 0.1 but less than about 0.8, (x+y) is more than 0.2 but less than 3, z is more than 0.05 but less than 3, and n is more than about 0.5 but less than about 9.

9. The catalyst component according to claim 8 , wherein step (c) comprises raising the temperature, thereby removing the alkanol and causing solidification of particles.

10. The catalyst component according to claim 1 , wherein the bidentate electron donor is selected from the group consisting of ethers, amines, silanes, carbamates, ketones, esters of aliphatic acids, alkyl and aryl esters of optionally substituted aromatic polycarboxylic acids, diol derivatives containing ester, carbamates, carbonates, amides groups or mixtures thereof.

11. The catalyst component according to claim 1 , wherein in a further step (d), the bidentate electron donor and optionally, a tetravalent titanium halide, are contacted with the solidified particles obtained from step (c).

12. The catalyst component according to claim 1 , wherein in step (b), the Mg alkoxide solution is mixed with TiCl 4 at a temperature of about −20° C. to about 30° C. and in the presence of a surfactant and in the successive step (c), precipitation of the solid catalyst components is obtained by slowly raising the temperature to at least 50° C.

13. The catalyst component according to claim 12 , wherein the bidentate electron donor is added to the Mg alkoxide solution prepared in step (a).

14. The catalyst component according to claim 1 , wherein the Mg alkoxide solution in a C 6 -C 10 aromatic liquid reaction medium prepared in step (a), is first contacted with the electron donor or precursor thereof, thereby obtaining a further solution; in step (b), the solution obtained in step (a) is reacted with titanium tetrahalide at a temperature greater than 10° C. and less than 60° C., thereby producing an emulsion of a denser, TiCl 4 /toluene-insoluble, oil dispersed phase having a Ti/Mg mol ratio 0.1 to 10 in an oil disperse phase having Ti/Mg mol ratio 10 to 100, in the presence of an emulsion stabilizer.

15. The catalyst component according to claim 14 , wherein in step (c), solidification of the dispersed phase droplets by heating is carried out at a temperature of 70-150° C.

Assignees

• Basell Poliolefine Italia Srl

Inventors

• Guidotti Simona
• Liguori Dario
• Morini Giampiero
• Vitale Gianni

Classifications

• C08F210/06

  Propene · CPC title

• C08F210/16 Primary

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

• C07F7/28 Primary

  Titanium compounds · CPC title

• C07F3/02

  Magnesium compounds · CPC title

• C07F9/94

  Bismuth compounds · CPC title