Propylene-based polymer with reduced high-molecular weight portion

Patent metadata

Field	Value
Publication number	US-9908952-B2
Application number	US-201415035649-A
Country	US
Kind code	B2
Filing date	Nov 14, 2014
Priority date	Nov 15, 2013
Publication date	Mar 6, 2018
Grant date	Mar 6, 2018

Abstract

The present disclosure provides a process for producing propylene-based polymer. The process includes contacting, under polymerization conditions in a gas phase polymerization reactor, propylene monomer and optionally one or more comonomers with a Ziegler-Natta catalyst composition. The process includes maintaining the temperature of a reaction zone of the reactor at a temperature from greater than 72° C. to less than or equal to 85° C., and forming a propylene-based polymer having a molecular weight (M w ) greater than 100,000, and a M z+1 /M z less than 2.20. The resultant propylene-based polymer is advantageous in fiber applications.

First claim

What is claimed is:

1. A process for producing propylene-based polymer comprising:
contacting, under polymerization conditions in a gas phase polymerization reactor having a reaction zone, propylene monomer and optionally one or more comonomers with a Ziegler-Natta catalyst composition;
maintaining the reaction zone of the gas phase polymerization reactor at a temperature from greater than 72° C. to less than 85° C.; and
forming a propylene-based polymer having a weight average molecular weight, M w , greater than 100,000, and a ratio of Z+1 average molecular weight to Z average molecular weight, M z+1 /M z , less than 2.20; and
further comprising visbreaking the propylene-based polymer and forming a propylene-based polymer with a weight average molecular weight to number average molecular weight ratio, M w /M n , less than 3.0;
wherein:
(a) the Ziegler-Natta catalyst composition comprises a phthalate-based internal electron donor and a mixed external electron donor comprising one or more alkoxysilanes and one or more activity limiting agents comprising a C 4 -C 30 aliphatic carboxylic acid ester; and
(b) xylene solubles content of the propylene-based polymer is 1.0 to 3.6 wt %.

2. The process of claim 1 , wherein the gas phase polymerization reactor is a gas phase fluidized bed polymerization reactor.

3. The process of claim 1 comprising maintaining the temperature of the reaction zone from greater than or equal to 75° C. to less than 85° C.

4. The process of claim 2
contacting propylene monomer with the Ziegler-Natta catalyst composition;
wherein the gas phase fluidized bed polymerization reactor is maintained at a temperature from greater than or equal to 75° C. to less than 85° C.; and
forming a propylene homopolymer with a M w greater than 200,000, a M w /M n , less than 6.0, and a M z+1 /M z less than 2.20; and
further comprising visbreaking the propylene homopolymer and forming a propylene homopolymer with a weight average molecular weight to number average molecular weight ratio, M w /M n , less than 3.0.

5. The process of claim 2 comprising
contacting propylene monomer with the Ziegler-Natta catalyst composition;
maintaining the temperature of the gas phase fluidized bed polymerization reactor from greater than or equal to 80° C. to less than 85° C.; and
forming a propylene homopolymer having a M w greater than 220,000, a M w /M n less than 6.0, and a M z+1 /M z less than 2.20; and

further comprising visbreaking the propylene homopolymer and forming a propylene homopolymer with a weight average molecular weight to number average molecular weight ratio, M w /M n , less than 3.0.

Assignees

• Grace W R & Co
• Grace W R & Co

Inventors

• Kaarto John K
• Van Egmond Jan W
• Lester Charles D

Classifications

• C08F2/00

  Processes of polymerisation · CPC title

• C08G85/00

  General processes for preparing compounds provided for in this subclass · CPC title

• C08F10/06 Primary

  Propene · CPC title

• C08F2/34

  Polymerisation in gaseous state · CPC title

• C08F210/06

  Propene · CPC title