Ziegler-Natta catalyst systems and polymers formed therefrom

Patent metadata

Field	Value
Publication number	US-9416202-B2
Application number	US-201113316662-A
Country	US
Kind code	B2
Filing date	Dec 12, 2011
Priority date	Jan 11, 2010
Publication date	Aug 16, 2016
Grant date	Aug 16, 2016

Abstract

Processes of forming catalyst systems, catalyst systems and polymers formed therefrom are described herein. The processes generally include providing a first compound including a magnesium dialkoxide, contacting the first compound with a second compound to form a solution of reaction product “A”, wherein the second compound is generally represented by the formula:

Ti(OR 1 ) 4 ;

wherein R 1 is selected from C 1 to C 10 linear to branched alkyls, contacting the solution of reaction product “A” with a first metal halide to form a solid reaction product “B”, contacting solid reaction product “B” with a second metal halide, to form reaction product “C” and contacting reaction product “C” with reducing agent to form a catalyst component.

First claim

What is claimed is:

1. A process of forming a catalyst system comprising:
providing a magnesium dialkoxide as a first compound;
contacting the magnesium dialkoxide with a third compound in the presence of a second compound to form a solution of reaction product “A”, wherein the second compound is TNBT or Ti(O-2-ethylhexyl) 4 , and the third compound is generally represented by the formula:
Al(OR 2 ) 3

wherein R 2 is selected from C 1 to C 10 linear or branched alkyls
contacting the solution of reaction product “A” with a first metal halide to form a solid reaction product “B”;
contacting solid reaction product “B” with a second metal halide to form reaction product “C”; and
contacting reaction product “C” with a reducing agent to form a catalyst component, wherein the reducing agent is selected from the group consisting of trimethyl aluminum, triisobutyl aluminum, triethyl aluminum, n-octyl aluminum and n-hexyl aluminum.

2. The process of claim 1 , wherein the magnesium dialkoxide is represented by the formula Mg(OEt) 2 .

3. The process of claim 1 , wherein the magnesium dialkoxide contacts the second compound in an equivalent of from about 0.75 to about 1.75.

4. The process of claim 1 , wherein the third compound comprises aluminum 2-ethylhexanoxide.

5. The process of claim 1 , wherein the second compound and the third compound contact one another prior to contact with the magnesium dialkoxide.

6. The process of claim 1 , wherein the first metal halide and the second metal halide each comprise TiCl 4 .

7. A Ziegler-Natta catalyst formed from the process of claim 1 .

8. The catalyst of claim 7 further comprising a particle size of at least about 5 microns.

9. The catalyst of claim 7 , wherein the catalyst exhibits a particle size that is greater than a particle size of the catalyst absent contact with the third compound.

10. A polymerization process comprising:
introducing an olefin monomer into a reaction zone;
contacting the olefin monomer with the catalyst of claim 1 to form a polyolefin; and
withdrawing the polyolefin from the reaction zone.

11. The process of claim 1 , wherein the reaction product “A” is formed from the second compound and the magnesium dialkoxide in a single process step.

Assignees

• Vizzini Kayo
• Knoeppel David
• Zhang Lei
• Tina Tech Inc

Inventors

• Vizzini Kayo
• Knoeppel David
• Zhang Lei

Classifications

• C08F2500/26

  Use as polymer for film forming · CPC title

• C08F110/02

  Ethene · CPC title

• C08F10/00 Primary

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

• C08F4/6555

  and magnesium or compounds thereof · CPC title

• C08F4/6548

  magnesium or compounds thereof, not provided for in C08F4/6543 or C08F4/6546 · CPC title