Process for preparing spherical polymerization catalyst components for use in olefin polymerizations

Patent metadata

Field	Value
Publication number	US-2016102156-A1
Application number	US-201414512130-A
Country	US
Kind code	A1
Filing date	Oct 10, 2014
Priority date	Oct 10, 2014
Publication date	Apr 14, 2016
Grant date	—

Abstract

A method of making a solid catalyst component for production of a polyolefin, including the steps of: a) dissolving a halide-containing magnesium compound in a mixture including alkylepoxide, an organic phosphorous compound, a carboxylic acid or anhydride, and a hydrocarbon solvent to form a homogenous solution; b) optionally treating the homogeneous solution with a halogenating agent; c) treating the homogenous solution with a first titanium halide compound in the presence of a surface modifier and optionally a first electron donor to form a solid precipitate, wherein, if present, the first electron donor is an ether; d) optionally treating the solid precipitate with a second electron donor; and e) treating the solid precipitate with a second titanium halide compound and optionally with a second electron donor to form the solid catalyst component.

First claim

1 . A method of making a solid catalyst component for production of a polyolefin, comprising
a) dissolving a halide-containing magnesium compound in a mixture comprising alkylepoxide, an organic phosphorous compound, a carboxylic acid or anhydride, and a hydrocarbon solvent to form a homogenous solution; b) optionally treating the homogeneous solution with a halogenating agent; c) treating the homogenous solution with a first titanium halide compound in the presence of a surface modifier and optionally a first electron donor to form a solid precipitate, wherein, if present, the first electron donor is an ether; d) optionally treating the solid precipitate with a second electron donor; and e) treating the solid precipitate with a second titanium halide compound and optionally with a second electron donor to form the solid catalyst component, wherein step b) is performed and/or the first electron donor is present in step c).

2 . The method of claim 1 , wherein the first electron donor is present in step c).

3 . The method of claim 1 , wherein step b) is performed.

4 . The method of claim 3 , wherein the halogenating agent is an organic or inorganic compound containing at least one halogen atom that can be transferrable to a magnesium atom.

5 - 8 (canceled)

9 . The method of claim 1 , wherein the hydrocarbon solvent is an aromatic solvent, non-aromatic solvent, or a mixture comprising an aromatic solvent and a non-aromatic solvent.

10 . The method of claim 9 , wherein the aromatic solvent comprises toluene or C 2 -C 20 alkylbenzene and the non-aromatic solvent comprises hexane or heptane.

11 - 13 . (canceled)

14 . The method of claim 1 , wherein the first electron donor is a di-(C 1 -C 12 ) alkyl ether.

15 - 18 . (canceled)

19 . The method of claim 1 , wherein said step c) comprises:
c1) mixing the homogenous solution with the first titanium halide compound in the presence of the surface modifier and the first electron donor; and c2) heating the mixture from step c1) to a temperature from 80° C. to 150° C. to obtain the solid precipitate.

20 . The method of claim 1 , wherein said step d) comprises:
d1) adding the second electron donor to a solution containing the solid precipitate to form a solid catalyst composition; and d2) bringing a temperature of the solid catalyst composition to from 80° C. to 150° C. and further treating with the second titanium halide compound and optionally the second electron donor to form the solid catalyst component.

21 . The method of claim 1 , wherein said step d) comprises:
d1) filtering out the precipitate; d2) optionally adding the second electron donor in a solvent to the solid precipitate to form a solid catalyst composition; and d3) bringing a temperature of the solid catalyst composition to from 80° C. to 150° C. and further treating with the second titanium halide compound and optionally with the second electron donor to form the solid catalyst component.

22 . The method of claim 1 , wherein the surface modifier is an acrylate-based additive.

23 - 24 . (canceled)

25 . The method of claim 1 , wherein the halide-containing magnesium compound is selected from the group consisting of magnesium chloride, magnesium bromide, magnesium iodide, and magnesium fluoride.

26 . The method of claim 1 , wherein the first titanium halide compound and the second titanium halide compound are each independently represented by:
Ti(OR) g X 4-g wherein each R group independently represents an alkyl group having 1 to 4 carbon atoms, X represents Br, Cl, or I, and g is a whole number satisfying the formula 0≦g≦4.

27 . (canceled)

28 . The method of claim 1 , wherein the organic phosphorous compound is represented by a structure:

wherein R 1 , R 2 , and R 3 are each independently selected from the group consisting of methyl, ethyl, and linear or branched (C 3 -C 10 )alkyl groups.

29 . The method of claim 1 , wherein the alkylepoxide is represented by

where “a” is from 1 to 5 and X is F, Cl, Br, I, or methyl.

30 . The method of claim 1 , wherein the carboxylic acid or anhydride is at least one member selected from the group consisting of acetic anhydride, phthalic anhydride, succinic anhydride, maleic anhydride, pyromellitic dianhydride, acetic acid, propionic acid, butyric acid, acrylic acid, and methacrylic acid.

31 . The method of claim 1 , wherein the second electron donor is at least one selected from the group consisting of carboxylic acid esters, ethers, and ketones.

32 - 35 . (canceled)

36 . The solid catalyst component produced by the method of claim 1 .

37 . A catalyst system for use in olefinic polymerization, comprising:
(i) said solid catalyst component of claim 36 ; (ii) an organoaluminum compound; and (iii) optionally an organosilicon compound.

38 - 40 . (canceled)

41 . A process for polymerizing or copolymerizing an olefin monomer, comprising the steps of:
(i) providing the catalyst system according to claim 36 ; (ii) polymerizing or copolymerizing the olefin monomer in the presence of the catalyst system to form a polymer or a copolymer; and (iii) recovering the polymer or copolymer.

42 . (canceled)

Assignees

• Basf Corp

Inventors

• Umezawa-Vizzini Kayo
• Marin Vladimir P
• Spencer Michael
• O'Reilly Neil J
• Hintolay Ahmed

Classifications

• C08F4/6465

  containing silicium · CPC title

• C08F4/651 Primary

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

• C08F2/38

  Polymerisation using regulators, e.g. chain terminating agents {, e.g. telomerisation} · CPC title

• C08F110/06 Primary

  Propene · CPC title

• C08F10/00

  Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond · CPC title