Catalyst system and a process for the production of a polyethylene in the presence of this catalyst system

Patent metadata

Field	Value
Publication number	US-9637571-B2
Application number	US-92239509-A
Country	US
Kind code	B2
Filing date	Mar 10, 2009
Priority date	Mar 14, 2008
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

The invention relates to a catalyst system comprising
I. a solid reaction product obtained by reaction of:
(a) a hydrocarbon solution comprising
(1) an organic oxygen containing magnesium compound or a halogen containing magnesium compound and (2) an organic oxygen containing titanium compound and
(b) a mixture comprising a metal compound having the formula MeR n X 3-n wherein X is a halogenide, Me is a metal of Group III of Mendeleev's Periodic System of Chemical Elements, R is a hydrocarbon radical containing 1-10 carbon atoms and 0≦n≦3 and a silicon compound of formula R m SiCl 4-m wherein 0≦m≦2 and R is a hydrocarbon radical containing 1-10 carbon atoms wherein the molar ratio of metal from (b): titanium from (a) is lower then 1:1 and
II. an organoaluminium compound having the formula AlR 3 in which R is a hydrocarbon radical containing 1-10 carbon atoms.

First claim

The invention claimed is:

1. A catalyst system comprising:
(I) a solid reaction product obtained by reaction of:
1) a hydrocarbon solution comprising:
(a) an organic oxygen containing magnesium compound; and
(b) an organic oxygen containing titanium compound; and

2) a mixture comprising a metal compound having the formula MeR n X 3-n , wherein X is a halogenide, Me is a metal of Group III of Mendeleev's Periodic System of Chemical Elements, R is a hydrocarbon radical containing 1-10 carbon atoms and 0≦n≦3, and a silicon compound of formula R m SiCl 4-m , wherein 0≦m≦2 and R is a hydrocarbon radical containing 1-10 carbon atoms, wherein the molar ratio of metal from 2) to titanium from 1) is lower than 1:1; and

(II) an organoaluminium compound having the formula AlR 3 in which R is a hydrocarbon radical containing 1-10 carbon atoms.

2. The catalyst according to claim 1 , wherein the reaction obtaining the solid reaction product further comprises
3) post treatment of the obtained solid reaction product with an aluminium compound having the formula AlR n Cl 3-n wherein R is a hydrocarbon radical containing 1-10 carbon atoms and 0≦n≦3.

3. The catalyst according to claim 1 , wherein the metal compound having the formula MeR n X 3-n is an aluminium compound having the formula AlR n X 3-n wherein X is a halogenide and R is a hydrocarbon radical containing 1-10 carbon atoms.

4. The catalyst according to claim 1 , wherein the molar ratio of chlorine from R m SiCl 4-m to oxygen from the organic oxygen containing magnesium and titanium compounds is lower than 3:1.

5. The catalyst according to claim 1 , wherein the molar ratio of magnesium to titanium is lower than 3:1.

6. The catalyst according to claim 1 , wherein the organic oxygen containing magnesium compound is a magnesium alkoxide.

7. The catalyst according to claim 6 , wherein the magnesium alkoxide is magnesium ethoxide.

8. The catalyst according to claim 1 , wherein the organic oxygen containing titanium compound is a titanium alkoxide.

9. The catalyst according to claim 8 , wherein the organic titanium alkoxide is Ti(OC 4 H 9 ) 4 .

10. The catalyst according to claim 1 , wherein the organoaluminium compound from (II) is triethylaluminium or triisobutyl aluminium.

11. A process for the production of a catalyst comprising:
a) first reacting an organic oxygen containing magnesium compound and an organic oxygen containing titanium compound;
b) followed by diluting with a hydrocarbon solvent, resulting in a soluble complex consisting of a magnesium alkoxide and a titanium alkoxide;
c) after which reacting the hydrocarbon solution of said complex and a mixture comprising a metal compound having the formula MeR n Cl 3-n , wherein Me is a metal of Group III of Mendeleev's Periodic System of Chemical Elements, R is a hydrocarbon radical containing 1-10 carbon atoms and 0≦n≦3, and a silicon compound of formula R m SiCl 4-m , wherein 0≦m≦2 and R is a hydrocarbon radical containing 1-10 carbon atoms.

12. The process for the production of the catalyst according to claim 11 , wherein the organic oxygen containing magnesium compound is a magnesium alkoxide and the organic oxygen containing titanium compound is a titanium alkoxide, and the metal compound is an aluminium compound having the formula AlR n Cl 3-n .

13. A process for the production of polyethylene comprising polymerising ethylene in the presence of a catalyst comprising:
(I) a solid reaction product obtained by reaction of:
1) a hydrocarbon solution comprising:
(a) an organic oxygen containing magnesium compound and
(b) an organic oxygen containing titanium compound; and

2) a mixture comprising a metal compound having the formula MeR n X 3-n , wherein X is a halogenide, Me is a metal of Group III of Mendeleev's Periodic System of Chemical Elements, R is a hydrocarbon radical containing 1-10 carbon atoms and 0≦n≦3, and a silicon compound of formula R m SiCl 4-m , wherein 0≦m≦2 and R is a hydrocarbon radical containing 1-10 carbon atoms, wherein the molar ratio of metal from 2) to titanium from 1) is lower than 1:1; and

(II) an organoaluminium compound having the formula AlR 3 in which R is a hydrocarbon radical containing 1-10 carbon atoms.

14. A process for the production of an ethylene polymer comprising polymerising ethylene in the presence of a catalyst comprising:
(I) a solid reaction product obtained by reaction of:
1) a hydrocarbon solution comprising:
(a) an organic oxygen containing magnesium compound and
(b) an organic oxygen containing titanium compound; and

2) a mixture comprising a metal compound having the formula MeR n X 3-m , wherein X is a halogenide, Me is a metal of Group III of Mendeleev's Periodic System of Chemical Elements, R is a hydrocarbon radical containing 1-10 carbon atoms and 0≦n≦3, and a silicon compound of formula R m SiCl 4-m , wherein 0≦m≦2 and R is a hydrocarbon radical containing 1-10 carbon atoms, wherein the molar ratio of metal from 2) to titanium from 1) is lower than 1:1; and

(II) an organoaluminium compound having the formula AlR 3 in which R is hydrocarbon radical containing 1-10 carbon atoms;
wherein the ethylene polymer has an average molecular weight higher than 280,000 g/mol and lower than 10,000,000 g/mol, an average particle size (D 50 ) in the range between 50 and 250 micrometer, and a bulk density in the range between 350 and 600 kg/m 3 .

15. The process of claim 14 , wherein the average particle size (D 50 ) is in the range between 50 and 200 micrometer.

16. The process of claim 14 , wherein the bulk density is in the range between 400 and 600 kg/m 3 .

17. The catalyst according to claim 1 , wherein when the catalyst is used in the production of polyethylene, the resulting polyethylene has a bulk density in the range between 350 and 600 kg/m 3 .

18. The catalyst according to claim 17 , wherein when the catalyst is used in the production of polyethylene, the resulting polyethylene has a bulk density in the range between 400 and 600 kg/m 3 .

19. The catalyst according to claim 1 , wherein n is less than 3.

20. The catalyst according to claim 1 , wherein m is greater than 0.

21. The catalyst according to claim 1 , wherein the metal compound comprises aluminium trichloride, ethyl aluminium dibromide, ethyl aluminium dichloride, propyl aluminium dichloride, n-butyl aluminium dichloride, isobutyl aluminium dichloride, diethyl aluminium chloride, diisobutyl aluminium chloride, triisobutyl aluminium, tri-n-hexyl aluminium, or a combination comprising one or more of the foregoing.

22. The catalyst according to claim 1 , wherein the ratio is less than or equal to 0.38:1.

23. The catalyst according to claim 1 , wherein the hydrocarbon solution consists essentially of the organic oxygen containing magnesium compound and the organic oxygen containing titanium compound.

Assignees

• Friederichs Nicolaas Hendrika
• Gerlofsma Raymond
• Saudi Basic Ind Corp

Inventors

• Friederichs Nicolaas Hendrika
• Gerlofsma Raymond

Classifications

• C08F2500/18

  Bulk density · CPC title

• C08F2500/01

  High molecular weight, e.g. >800,000 Da. · CPC title

• C08F10/02 Primary

  Ethene · CPC title

• C08F2500/24

  Polymer with special particle form or size · CPC title

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title