Formation of a Ziegler-Natta catalyst

Patent metadata

Field	Value
Publication number	US-9624321-B2
Application number	US-201414304358-A
Country	US
Kind code	B2
Filing date	Jun 13, 2014
Priority date	Jun 13, 2014
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

A process of forming a Ziegler-Natta catalyst component is disclosed. The process includes contacting an alkyl magnesium compound with an alcohol and a first organoaluminum compound to form a magnesium dialkoxide compound and contacting the magnesium dialkoxide compound with a titanating agent to form reaction product “A.” The process further includes reacting reaction product “A” with a halogenating agent to form reaction product “B” and reacting reaction product “B” with a second organoaluminum compound to form a single halogenated catalyst component.

First claim

What is claimed is:

1. A process of forming a Ziegler-Natta catalyst component comprising:
contacting an alkyl magnesium compound with an alcohol and a first organoaluminum compound to form a magnesium dialkoxide compound;
contacting the magnesium dialkoxide compound with a titanating agent to form reaction product “A” without contacting a halogenating agent;
reacting reaction product “A” with a halogenating agent to form reaction product “B”; and
reacting reaction product “B” with a second organoaluminum compound to form a single halogenated catalyst component.

2. The process of claim 1 , wherein the first organoaluminum compound is trimethyl aluminum (TMA), triisobutyl aluminum (TIBAl), triethyl aluminum (TEAl), tri-n-octylaluminum (TNOAl), n-octyl aluminum or n-hexyl aluminum.

3. The process of claim 1 , wherein the second organoaluminum compound is trimethyl aluminum (TMA), triisobutyl aluminum (TIBAl), triethyl aluminum (TEAl), tri-n-octylaluminum (TNOAl), n-octyl aluminum or n-hexyl aluminum.

4. The process of claim 1 , wherein the alkyl magnesium compound is butyl ethyl magnesium (BEM), diethyl magnesium, dipropyl magnesium or dibutyl magnesium.

5. The process of claim 1 , wherein the alcohol is butanol, isobutanol, or 2-ethylhexanol.

6. The process of claim 1 , wherein the titanating agent is Ti(OiPr) 4 , or Ti(OBu) 4 .

7. The process of claim 1 , wherein the halogenating agent is a titanium halide.

8. The process of claim 7 , wherein the halogenating agent is titanium tetrachloride (TiCl.sub.4).

9. The process of claim 1 further comprising contacting the single halogenated catalyst component with an activator.

10. The process of claim 9 , wherein the activator is TiBAl.

11. A process of forming a polyolefin comprising:
supplying a Ziegler-Natta catalyst, wherein the Ziegler Natta catalyst comprises a Ziegler Natta catalyst component made by:
contacting an alkyl magnesium compound with an alcohol and a first organoaluminum compound to form a magnesium dialkoxide compound;
contacting the magnesium dialkoxide compound with a titanating agent to form reaction product “A” without contacting a halogenating agent;
reacting reaction product “A” with a halogenating agent to form reaction product “B”; and
reacting reaction product “B” with a second organoaluminum compound to form a single halogenated catalyst component; and
contacting the Ziegler Natta catalyst with an olefin monomer in a reactor under reactor conditions to form the polyolefin.

12. The process of claim 11 , wherein the olefin monomer is ethylene and the polyolefin is polyethylene.

13. The process of claim 12 , wherein the fluff bulk density of the polyethylene is between 0.33 g/mL and about 0.37 g/mL.

14. The process of claim 12 , wherein the fluff % fines (<63 .mu.m) of the polyethylene is from about 1.5 to 10.

15. The process of claim 12 , wherein the fluff average particle size (D50) of the polyethylene is from 105 .mu.m to about 150 .mu.m.

16. The process of claim 12 , wherein the molecular weight distribution (M.sub.w/M.sub.n) of the polyethylene is from about 4.5 to about 6, as measured by GPC.

17. The process of claim 12 , wherein the density of the polyethylene as measured by ASTM D-792 is from about 0.95 g/cc to about 0.965 g/cc.

18. The process of claim 12 , wherein the melt index (MI2) of the polyethylene as measured by ASTM D-1238 is from about 0.30 dg/min to 11 dg/min.

19. The process of claim 12 , wherein the high load melt index (HLMI) of the polyethylene from is from 10 dg/min to 300 dg/min, as measured by ASTM D-1238.

Assignees

• Fina Technology

Inventors

• Zhang Lei
• Rauscher David J

Classifications

• C08F4/6421

  Titanium tetrahalides with organo-aluminium compounds · CPC title

• C08F2500/24

  Polymer with special particle form or size · CPC title

• C08F2500/18

  Bulk density · CPC title

• C08F110/02 Primary

  Ethene · CPC title

• C08F2500/12

  Melt flow index or melt flow ratio · CPC title