FI86643B - TILL SIN MORFOLOGI SFAERISK BAERARE FOER EN KATALYSATOR FOER POLYMERISERING AV ALFA-OLEFINER OCH KATALYSATORER I VILKAS FRAMSTAELLNING DESSA BAERARE HAR ANVAENTS. - Google Patents

Abstract

Spherical catalyst support manufactured by reaction of an organic chlorine compound in the presence of an electron donor and of a mixture of an alkylmagnesium compound and of an organic aluminium compound, characterised in that the organic chlorine compound, in combination with an electron donor, is reacted with the preliminary mixture of alkylmagnesium compound, aluminoxane and/or aluminosiloxane and optionally of electron donor. This support, subjected to a second activation with a chlorine compound, is impregnated with a transition metal halide.

Description

1 86643

Spherical support for a catalyst for the polymerisation of alpha-olefins and catalysts prepared using these supports

The present invention relates to a spherical support of a catalyst for the polymerization of alpha-olefins prepared by reacting an organochlorine compound in the presence of an electron donating agent with a mixture of an alkylmagnesium compound and an organoaluminum compound.

The invention also relates to a spherical catalyst having a morphology obtained starting from this support after the support has been treated a second time with an organochlorine compound before impregnation with titanium halide. The catalyst obtained can be used to readily prepare polyolefins having a wide molecular weight distribution range in the presence of a cocatalyst, by polymerizing or copolymerizing alpha-olefins of the formula CH2 = CHR, in which R is a hydrogen atom or an alkyl radical containing 1- 6 carbon atoms.

FR Patent 2,529,207 discloses spherical supports with a morphology for the preparation of catalysts for use in the polymerization of alpha-olefins. These carriers are obtained by reacting an organochlorine compound, in the strict presence of ether oxide, with an organomagnesium compound of the formula R: Mg R 2 x Al (R 3) 3, in which R x, R 2 and R j are alkyl radicals.

Such a process for preparing a support can provide a catalyst in which the polymers prepared have a narrow molecular weight distribution range or are poorly dispersed. The invention is mainly characterized by what is stated in the characterizing part of claims 1 and 3.

2 86643

The spherical support of the catalyst is prepared according to the invention by reacting an organochlorine compound, in the presence of an electron donating agent, with a mixture of an alkylmagnesium compound and an organoaluminum compound, and the process is characterized by reacting an organic chlorine compound combined with an electron donating compound is an alkylmagnesium compound, an aluminum oxane and / or an aluminum oxyoxane a and optionally an electron donating agent.

This described support as such, impregnated with catalytically active substances and due to the presence of aluminum oxane and / or aluminum oxane, alone affects the molecular weight distribution range of the finally obtained polymer in the presence of this catalyst. However, the activation of the support with a new chlorine compound makes it possible to obtain a catalyst in which the morphology of the support remains intact and productivity is improved. In addition, it makes it possible to increase the bulk density of the final polymer.

More specifically, the aluminum magnesium compound is premixed with aluminum oxane and / or aluminum aluminum oxane, preferably dissolved in an inert solvent such as a hydrocarbon, for example hexane, and optionally an electron donating agent is present. When the mixture is complete, the organochlorine compound diluted in the electron donor is reacted. The spherical support formed at the end of the reaction, suspended in the reaction medium, is filtered, washed with an inert liquid and finally dried. This gives a pellet-like support having a specific female surface area of between 1 and 100 μm / g and an average particle diameter of between 5 and 100 μg and most usually between 10 and 50 μm. The particle size distribution range of the supports and thus of the final catalysts is very narrow, generally less than 5. This extent of the particle size distribution range is characterized by a diameter ratio of 3: 86643. The diameters are taken from a granulometric curve which indicates the cumulative percentage as a function of the increasing diameter of the particles.

The alkylmagnesium compound used corresponds to the formula Rx Mg R2, wherein Rx and R2 are alkyl radicals having 1 to 12 carbon atoms.

The aluminoxane which may be added to the carrier composition is selected from compounds of the formula: R 'r -} R' \ /

AI - 0 - AI - 0 - AI

/ I n \ R "R 'J R" wherein R' is an alkyl radical containing 1-16 carbon atoms and the radicals R '' together form the radical -O- or each represent the radical R ', and n is an integer from 0 to 20.

The aluminum siloxane that can be added to the carrier composition is selected from substances corresponding to the formula:

Ri R3 \ /

Al-O-Si-R 4 / R 2 where R 1, R 2, R 3, R 4 and R 5, either identical or different, represent an alkyl radical containing 1 to 12 carbon atoms and preferably 1 to 6 carbon atoms, or still hydrogen, but preferably no more than three hydrogen atoms per mole of derivative, or finally more chlorine, but preferably no more than three moles of chlorine per mole of derivative.

The organic chlorine compound used as the chlorinating agent of the alkylmagnesium derivative of the aluminum compound is selected from alkyl orides in which the alkyl radical is primary, secondary or tertiary, from alkyl polyhalides or even from acid chlorides.

Preferred compounds are tert-butyl ori di, n-butyl-chloro di, thionyl ori di, benzoyl orid, dichloroethane.

The chlorinating agent of the mixture of the magnesium compound and the organic compound of aluminum is combined with at least one electron donating agent selected from aliphatic or cyclic ethers, such as diisoamyl ether and sec-butyl ether.

The electron donating agent, optionally combined with the mixture of the alkylmagnesium compound and the organoaluminum compound, is preferably identical to the electron donating agent combined with the chlorinating agent. However, it is not excluded that any known compound that donates electrons is incorporated into this mixture. It is preferably selected from aliphatic or aromatic carboxylic acids and their alkyl esters, aliphatic or cyclic ethers, ketones, vinyl esters, acrylic derivatives, in particular alkyl acrylates or methacrylates and silanes. Particularly suitable electron donors are compounds such as methyl paratoluate, ethyl benzoate, ethyl or butyl acetate, ethyl ether, ethyl paranisate, di-butyl phthalate, dioctyl phthalate, di-iobutyl phthalate, isopropyl acetone, tetrahydrofuran, dioxaurea, dioxa , phenyltriethoxysilane. Esters can also be used as adducts with halides of Lewis acids other than magnesium dihalides.

5,86643

In order to control the morphology of the final carrier well, it is important to combine the ingredients in suitable amounts.

Thus, a molar ratio of Mg / Al of between 5-200 and preferably between 10-80 is recommended. Due to the insufficient concentration of the organochlorine compound, a sufficient degree of chlorination of the organomagnesium derivative cannot be achieved in the first chlorination, resulting in a support containing too much organic compounds. The concentration of chlorine used in this step is preferably such that the molar ratio Cl / Mg is between 2-4.

The amount of electron donor used may be such that the molar ratio of total electron donor to magnesium is between 0.01 and 5, and the ratio of aliphatic or cyclic ether to magnesium is at least 0.01.

The supports obtained according to the invention are particularly suitable for the preparation of Ziegler-Natta catalysts for the polymerization of alpha-olefins based on a halide of a transition metal such as Cr, V, Zr and preferably Ti. These catalysts are generally obtained by impregnating the MgCl 2 support with, for example, T i Cl a v u 11 a.

4

As already indicated, it is recommended that before impregnating the support with the transition metal halide, it be reactivated by a second treatment with a chlorine compound. To this end, the support is resuspended in a suspension, optionally in an inert liquid such as a hydrocarbon if the chlorine compound is sufficiently fluid, and then re-contacted with the chlorine compound to ensure complete chlorination of the support and especially the metal bonds.

6 86643 The degree of this chlorination can be monitored by hydrolysis of the resulting support. In the case of overchlorination of the support, the amount of halogen used is irrelevant, since any excess can be removed afterwards, possibly by washing.

The chlorine compound used in this step is identical or different from that previously used. In this case, it may be not only an organic compound but also an inorganic halogen compound. It can be, for example: MCI, a halogenated hydrocarbon such as CC1 or still SiCl, SOCl.

4 4 2 After this step, the support may be filtered, washed and dried slightly and then impregnated with a transit metal halide of special formula

Ti (OR) X, where R is an alkyl radical containing 1-12 x 4-x carbon atoms and X is halogen and predominantly TiCl. The impregnation 4 can be carried out in a classical manner by adding a sufficient amount of transition metal halide to the support, optionally in an inert solvent, to obtain a homogeneous suspension. It is generally sufficient to keep the suspension under stirring for a few hours at a temperature below 150 ° C to impregnate the support with the transition metal halide. The catalyst is then filtered and washed with an inert liquid until the halide has been removed to the last minute. It is also not excluded that a second impregnation with the transition metal halide is carried out at this stage, followed by filtration and washing to modify the kinetics of the catalyst and the physical properties of the resulting polymers.

The polymerization ratios of Al-fa-olefins with the catalysts according to the invention are the same as those already known from the prior art. The polymerization can be carried out either in the liquid phase with or without an inert dissolving hydrocarbon such as hexane or heptane, or in the gas phase. The polymer is 7 86643 ......., 0 0 γοιnti 1ampoti1 a is usually between 40 -150 C and the special o o ti between 50 -90 C. The polymerization can still take place in the pulp oo at a pressure of 100-300 bar at a temperature of 130 - 350 C.

The polymers obtained with these catalysts have the shape of spherical particles, which gives them a typical good flowability.

The tests of the following example illustrate the invention without, however, limiting it.

Example 1 A. Preparation of the carrier

Work in a 1 liter glass reactor which is evacuated with nitrogen and equipped with a stirrer 1a and a temperature control device. To this reactor, which is swept continuously by a stream of nitrogen, is added a sufficient amount of magnesium compound, aluminum oxane or aluminum alumina, the first electron donating agent, dry hexane to reach the desired volume, i.e. a concentration of Mg of 0.5 mol per liter. This solution is stirred at 50 ° C for about 16 h.

The mixture of the electron donating agent and the tert-butyl chloride is slowly injected using a syringe fitted to the perfusion device. When the injection is complete, stirring and maintaining the temperature for an additional 3 h.

The reaction intervals are filtered at ambient temperature. Wash several times with hexane and the recovered powder may be dried under a stream of nitrogen at 60 ° C (Table A).

B. Catalyst Preparation

Work in a glass 500 ml reactor equipped with a stirrer and a temperature control device. To this 8 86643 reactor, which is evacuated by continuous sweeping with a stream of nitrogen, a support is added, then either hexane, which has been dried and degassed with nitrogen to form a suspension. , which is stirred slowly and bubbled with anhydrous HCl for 30 minutes at ambient temperature, or a liquid chlorinating agent is added in which,. o the carrier remains in suspension for one hour at 50 ° C.

The treated support is filtered, washed with dry hexane and degassed after drying slightly. It is then resuspended homogeneously in TiCl with gentle but effective mixing. Impregnation takes place in the temperature range 60 -90 C within 2 h. The reaction medium is then filtered hot; the recovered catalyst is washed at ambient temperature with hexane until all

The traces of TiCl have escaped into the washing liquid. Catalyst 4 ° can be dried at about 60 ° C and then stored under an inert atmosphere or suspended in an inert hydrocarbon (Table B).

C. Polymerization of ethylene

Work in a stainless steel 5 liter reactor equipped with a stirrer rotating at 500 rpm and a temperature controller. The reactor is deaerated with nitrogen and purged with hydrogen gas at ambient temperature and 1000 ml of hexane and cocatalyst are added.

4.6 bar of hydrogen, 6.4 bar of ethylene are then injected sequentially into the reactor, then 20-30 mg of catalyst suspended in hexane. The temperature of the medium is raised to 80 ° C and the pressure is kept constant by continuously introducing ethylene. After 1.5 h, the polymerization is stopped by the addition of methanol and HCl. The polymer is recovered and dried (Table C).

The following tables illustrate these different steps.

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Example 2

To a dry 8.2-liter, deaerated reactor, nitrogen is added with stirring at 350 rpm in succession at 40 ° C: 3 l of dry hexane 10.5 mM triisobutylaluminium (TIBA) diluted in hexane 2 , 1 M / l 0.93 g of catalyst for Example 1 4 0.5 abs. bars of hydrogen 3 abs. bars of nitrogen.

Homogenize for 5 min and add ethylene at a flow rate of 10 1 / h over 30 min, then 65 1 / h over 2 h.

The addition of ethylene is stopped and the total pressure drops. The reactor is degassed with nitrogen, stirring more slowly, at 150 rpm.

o The temperature is raised to 60 ° C. Hexane is removed by a stream of nitrogen. After complete evaporation of the solvent, 164 g of the prepolymer, which is morphologically spherical and without aggregates, is recovered, the degree of prepolymerization is 176 g of prepolymer per gram of catalyst and the bulk density (MVA) is 0.302.

Copolymerization of ethylene-butene-1 in the gas phase

Work in a pre-dried 8.2 L reactor equipped with a stirrer running at o 400 rpm and maintained at 85 ° C throughout the polymerization.

In a reactor maintained at a reduced pressure of 1.33 Pa and containing 100 g of polyethylene at the bottom of the tank, inject: 13 86643 - 1 abs. bar of butene-1 - a mixture having a spherical protective effect and containing: 0.4 mM TIBA diluted in 2.1 M / l hexane and 0.027 mM phenyltriethoxysilane (PTES) - 1.5 abs. bar of butene-1 - 2 abs. bars of hydrogen - 13.5 abs. bars of ethylene.

10 g of the above active prepolymer are then added to the reactor, on which a mixture of 0.4 mM TIBA diluted with 2.1 M / l hexane and 0.027 mM PTES is impregnated. This addition of prepolymer is carried out under nitrogen pressure until the total pressure inside the reactor rises to 21 abs. bar. The pressure in the reactor is maintained at this value by injecting ethylene and butene-1 in a molar ratio of butene-1 / ethylene = 0.0466.

After 4 hours of polymerization, the reactor is vented and cooled.

928 g of copolymer which is morphologically spherical are recovered, excluding the starting charge. The productivity is 16,332 g of polyethylene per g of catalyst a.

Typical physical properties of the copolymer are: MI = 0.6 2

Density = 0.924 0 = 840 μ m MVA = 0.462 g / cm 3

Claims (8)

1. In the case of a morphological sphere which is a catalyst for the polymerization of an alpha-olefin, the genomic frameworks of the genome are represented by an organic chlorine and a nerve with an electron donor with an alkylation of the alkyl, anhydrous and organic In the case of organic chlorine generators with an electron donor, the equivalents of the electron donor, preferably with an alkylmagnesium phase, aluminum oxide and / or aluminum siloxane and, if appropriate, an electron donor, can be used as an active substance. A spherical catalyst support for the polymerization of alpha-olefins prepared by reacting an organochlorine compound in the presence of an electron donor with a mixture of an alkylmagnesium compound and an organoaluminum compound, characterized in that the organochlorine compound is reacted with an electron donor with a mixture containing an alkylmagnesium compound, aluminoxane and / or aluminum siloxane and optionally an electron donating agent, after which the resulting support is activated a second time with the chlorine compound. 2. The preparation of an alpha-olefin genome impregnated with a polymer-containing metal halide 1 by means of a catalyst based on the polymerization of an alpha-olefin genome. 86643 BC Use of a support according to claim 1 for the preparation of a catalyst for the polymerization of alpha-olefins by impregnating a support according to claim 1 with a halide of a transition metal. 3. Development of an alpha-olefin genome for the polymerization of an alpha-olefin genome by means of an organic chlorination of a neuron from an electron donor with a blending of an alkylmagnesium for the production of organic aluminum the blending of aluminum oxide and / or aluminum siloxane, the alkylmagnesium formation and, if appropriate, the electron donor are mediated by organic chlorination, the utilization of which is electron donor, and which is the case after the action of the organic chlorine filter, suspensionsmed in the environ- mental environment, in which case they are activated. 3. A process for preparing a spherical support for a catalyst used in the polymerization of alpha-olefins by reacting an organochlorine compound in the presence of an electron donor with a mixture of an alkylmagnesium compound and an organoaluminum compound, characterized in that a mixture of aluminum is reacted with and / or aluminum siloxane, an alkylmagnesium compound and optionally an electron donor, with an organochlorine compound diluted in the electron donor, and that after the reaction of the organochlorine compound the support is filtered, washed and optionally dried and resuspended in a medium containing the chlorine compound, re. 4. A method according to claim 3, which comprises the use of organic aluminum and alkylmagnesium in the form of a molar form of Mg / Al 5-200. Process according to Claim 3, characterized in that the organoaluminum compound and the alkylmagnesium compound are used in a molar ratio of Mg / Al of 5 to 200. 86643 5. A patent according to claim 3 or 4, which comprises the use of an electron donor and a molar electrode and a magnesium oxide of 0.01 and 5 and a molar gel and an electron donor or an aliphatic or cyclic ether or more. Process according to Claim 3 or 4, characterized in that the amount of electron-donating substance used is such that the molar ratio of total electron-donating substance to magnesium is between 0.01 and 5 and the molar ratio of electron-donating aliphatic or cyclic ether to magnesium is at least 0. 01. 6. A compound according to claims 3-5, which comprises a game of organic chlorination, which comprises chlorination of organic aluminum and alkylmagnesium, preferably having a molar content of Cl / Mg, 4. Process according to one of Claims 3 to 5, characterized in that the amount of the organochlorine compound used in the first chlorination of the mixture of the organoaluminum compound and the alkyl-magnesium compound, calculated in a molar ratio of Cl / Mg, is between 2 and 4. 7. A process for the further preparation of polymerisation of an alpha-olefin catalyst, the reaction of which is preferably carried out by patenting 3-6, preferably having halogenated and halogenated metals. Process for the preparation of a catalyst for the polymerization of alpha-olefins, characterized in that the support obtained according to one of Claims 3 to 6 is impregnated by means of a transition metal halide. Process according to Claim 7, characterized in that the support is impregnated with a titanium halide. 8. A preferred embodiment of claim 7, which comprises impregnating titanium halides.