Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/04—Monomers containing three or four carbon atoms
  • C08F110/06—Propene

Definitions

• This invention relates to the synthesis of a catalyst for the polymerization of propylene.
• This catalyst has high activity, and produces a polymer product having high stereospecificity and high bulk density.
• the catalyst's activity is long lived and it shows a good temperature response. All of these features are desirable for a commercial propylene polymerization catalyst.
• the present invention relates to a process for forming a propylene polymerization catalyst.
• This process comprises: forming a combination of titanium tetrachloride, a soluble or insoluble magnesium-containing compound that can be converted to magnesium dihalide, such as a magnesium chloroalkoxide, and an internal electron donor, such as phthalate ester, in an alkylbenzene solvent and bringing that combination to elevated temperature to form an intermediate product which is separated by, for example decantation; washing the intermediate product with an aromatic hydrocarbon solvent at elevated temperature to produce a washed product and a supernatant followed by decantation of the supernatant therefrom; treating the washed product with titanium tetrachloride in an alkylbenzene solvent, preferably two or three more times, to form a treated product and a supernatant followed by heating of the treated product and supernatant, decantation of the supernatant therefrom, and washing of the treated product with an aromatic hydrocarbon solvent
• the soluble or insoluble magnesium-containing compound that can be converted to magnesium dihalide can be selected from one or more of the following types of compound: magnesium dialkoxides (e.g., magnesium diethoxide); chloromagnesium alkoxides (e.g., chloromagnesium ethoxide); magnesium dihalide electron donor adducts (e.g., MgCl 2 (EtOH) x and MgCl 2 (THF) x , where THF is tetrahydrofuran and x in both cases is ⁇ 0.5; alkylmagnesium halides (“Grignards”, such as chlorobutylmagnesium; and dialkylymmagnesium compounds, such as butylethylmagnesium.
• magnesium dialkoxides e.g., magnesium diethoxide
• chloromagnesium alkoxides e.g., chloromagnesium ethoxide
• magnesium dihalide electron donor adducts
• the number of carbon atoms in the alkoxide/alkyl moiety or moieties will range from one to about twelve, preferably four. Any of such precursors can be supported on an inert carrier, such as silica.
• the internal electron donor can be selected from the known types of internal donor including the following classes: the phthalates and their derivatives; the benzoates and their derivatives; the silanes and siloxanes; and the polysilanes and polysiloxanes.
• the selected magnesium dichloride source compound cannot be a magnesium dialkoxide when the selected internal donor is a halo phthaloyl derivative.
• the process of this invention produces a polymerization catalyst that comprises a titanium compound having at least one titanium-halogen bond that is supported on an activated, amorphous magnesium dihalide support that is essentially free of alkoxy functionality, the titanium metal content in the catalyst preferably being no more than about 2 wt %, based on the weight of the support, and an internal donor, such as a phthalate ester donor.
• the catalyst of the present invention is made using a series of multiple treatment cycles, each of which involves the reaction of mixtures of titanium tetrachloride and an alkylbenzene solvent, such as toluene, with a support precursor followed by treatment of the solid with alkylbenzene solvent. These reaction steps are carried out at elevated temperature. During the first titanium tetrachloride/alkylbenzene solvent reaction step, an internal phthalate ester donor, such as the preferred di-isobutylphthalate, is added. If the ultimate polymer product that is to be produced is to have desirable particle size and morphology characteristics, an appropriate particle size and morphology-controlled support precursor needs to be used. The treatment cycles then need to be carried out in such a manner as to preserve these features in the final catalyst so that the polymer product replicates those features.
• an alkylbenzene solvent such as toluene
• the initial step of the process of the present invention involves forming a combination of titanium tetrachloride, magnesium chloroalkoxide, for example, and phthalate ester in an alkylbenzene solvent and bringing that combination to elevated temperature to form an intermediate product.
• the preferred magnesium chloroalkoxide will contain from one to about twelve carbon atoms in the alkyl moiety therein.
• the most preferred magnesium chloroalkoxide is magnesium chloroethoxide.
• Toluene has been found to be a preferred alkylbenzene solvent, with xylene, ethylbenzene, propylbenzene, isopropylbenzene, and trimethylbenzene also being useful.
• the preferred phthalate ester may contain from one to about twelve carbon atoms in the alkyl groups therein, with representative compounds including dimethyl phthalate, diethyl phthalate, di-n-propyl phthalate, di-isopropyl phthalate, di-n-butyl phthalate, di-butyl phthalate, di-tert-butyl phthalate, diisoamyl phthalate, di-tert-amyl phthalate, di-neopentyl phthalate, di-2-ethylhexyl phthalate, and di-2-ethyldecyl phthalate.
• the donor can be added at room temperature to the other components and the mixture can then be brought to elevated temperature (for example, at about 100° C. to about 140° C., preferably from about 110° C. to about 120° C.) or it can be added to the other two components either at room temperature and heated up to about 100° C. or can be added to those components after they have been heated to a desired temperature.
• elevated temperature for example, at about 100° C. to about 140° C., preferably from about 110° C. to about 120° C.
• the amount of titanium tetrachloride to alkylbenzene solvent will generally range from about 40% to 80% on a volume basis and, generally, from about three to about four treatment steps have been found to be adequate.
• the volume of titanium tetrachloride and solvent to grams of support precursor that is employed will generally be from about 5 to about 10 milliliters of titanium tetrachloride and solvent per gram of support precursor.
• the combination of components is preferably held together for up to about ten hours, preferably from about one to about two hours and is agitated.
• the intermediate solid product from this initial reaction step is then recovered after the supernatant is decanted.
• the intermediate product from the initial step is then washed with an aromatic hydrocarbon solvent, such as an alkylbenzene solvent (for example, toluene), at elevated temperature (e.g., from about 100° C. up to the boiling point of the solvent) to produce a washed product and a supernatant phase.
• an aromatic hydrocarbon solvent such as an alkylbenzene solvent (for example, toluene)
• elevated temperature e.g., from about 100° C. up to the boiling point of the solvent
• the washing can be practiced in up to about three separate washing steps.
• the supernatant in each washing step is decanted from the washed product. This washing serves to remove undesirable by-products that contain titanium.
• the volume of alkylbenzene solvent that is used per gram of support precursor in this step will generally range from about 5 to about 25 milliliters per gram.
• the washed product from the preceding step is then treated with titanium tetrachloride in an alkylbenzene solvent of the type previously described under the previously described conditions to form a treated product and a supernatant.
• This step converts unreacted alkoxide moieties of the starting magnesium chloroalkoxide reagent and extracts undesired titanium-containing by-products.
• This combination is then heated (e.g., at from about 100° C. to about 140° C.) followed by decantation of the supernatant phase that exist and washing of the treated product with an aromatic hydrocarbon solvent, preferably in a washing cycle of from one to two step(s) each.
• the product from the preceding step then has an aliphatic hydrocarbon solvent, such as hexane, added to it with decantation of the resulting supernatant phase therefrom.
• an aliphatic hydrocarbon solvent such as hexane
• Washing of the catalyst with aliphatic solvent serves to remove free titanium tetrachloride and residual aromatic solvent. This forms a washed product that can be used as the catalyst.
• An optional final step is the addition of mineral oil to the washed product from the preceding step to form a mineral oil/catalyst slurry that can be employed as the propylene polymerization catalyst. Drying of this slurry is usually avoided since it can result in a substantial decrease in catalyst activity (e.g., up to as much as 50%).
• the catalyst composition that can be formed from the previously described process appears to be a novel composition of matter in certain embodiments. It comprises a titanium compound having at least one titanium-halogen bond which is supported on an activated, amorphous magnesium dihalide support that is essentially free of alkoxy functionality.
• the catalyst composition has the following physical parameters: weight percent titanium—from about 1% to about 4%; weight percent phthalate ester—from about 10% to about 25%; phthalate ester to titanium molar ratio—from about 0.9 to about 2; weight percent magnesium—from about 14% to about 23%; magnesium to titanium molar ratio—from about 7 to about 30; surface area—from about 250 m 2 /gm to about 500 m 2 /gm; pore volume—from about 0.2 cc/gm to about 0.5 cc/gm; and average pore diameter—no more than about 50 Angstroms.
• More preferred embodiments of the catalyst composition have the following physical parameters: weight percent titanium—less than about 2.0%, most preferably from about 1% to about 2.5%, ; weight percent phthalate ester—from about 10% to about 20%; phthalate ester to titanium molar ratio—from about 1 to about 1.9; weight percent magnesium—from about 18% to about 21%; magnesium to titanium molar ratio—from about 14 to about 29; surface area—from about 300 m 2 /gm to about 500 m 2 /gm; pore volume—from about 0.2 cc/gm to about 0.4 cc/gm; and average pore-diameter—no more than about 35 Angstroms.
• a 4 liter autoclave equipped with an agitator was purged with nitrogen until oxygen and water have been reduced to acceptable levels. Then, under a N 2 purge, 50 ml of purified hexane was added to the reactor, followed by 7.0 mmole of TEAL and 0.48 mmole of dicyclopentyldimethoxy-silane.
• the reactor was closed and 2.5 1 of purified propylene was added, followed by 3.6 1 (STP) of H 2 . The contents of the reactor were stirred and were heated to 70° C. The reaction mixture was maintained at 70° C. for one or two hours. The reactor was then vented and cooled.
• the resulting polymer was collected and dried.
• the polymer was weighed and an activity, defined as kg polymer/g catalyst charged was calculated.
• the polymer poured bulk density (PBD) and total xylene insolubles (TXI) were measured.
• the controlled particle size distribution and morphology of the starting support precursor was maintained in the polymer particles. The results of these tests were shown in Table 1. In many cases, 2-3 tests were run on each catalyst and the average results of these tests were reported.
• a catalyst preparation was carried out using the procedure described in Example 1, except that 25 ml of toluene and 25 ml of TiCl 4 were used in the reaction steps. Analysis of the solid catalyst component showed it to contain 21 wt % Mg and 1.5 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 1, except that 20 ml of toluene and 30 ml of TiCl 4 were used in the reaction steps, and only 1 ⁇ 200 ml toluene treatment was used after each TiCl 4 /toluene reaction.
• Analysis of the solid catalyst component showed it to contain 19 wt % Mg and 1.8 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 1, except that the reactor was a 250 ml round bottom flask, 10 ml of toluene and 40 ml of TiCl 4 were used in the reaction steps, and 2 ⁇ 100 ml toluene treatments were used after each TiCl 4 /toluene reaction. Analysis of the solid catalyst component showed it to contain 19 wt % Mg and 1.6 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a solid catalyst component was synthesized following the procedure described in Example 1, except that the reactor was a 250 ml round bottom flask and 2 ⁇ 100 ml toluene treatments were used after each TiCl 4 /toluene reaction step. Analysis of the solid catalyst component showed it to contain 19 wt % Mg and 1.5 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• Example 1 The procedure described in Example 1 was used to prepare a catalyst, except that the reactor was a 250 ml round bottom flask and one 100 ml toluene treatment was used after each TiCl 4 /toluene reaction step. Analysis of the solid catalyst component showed it to contain 17 wt % Mg and 3.0 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 3, except that the reactor was a 250 ml round bottom flask and 2 ⁇ 100 ml toluene treatments were used after each TiCl 4 /toluene reaction step. Analysis of the solid catalyst component showed it to contain 20 wt % Mg and 1.7 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a solid catalyst component was synthesized following the procedure described in Example 3, except that the reactor was a 250 ml round bottom flask and 1 ⁇ 100 ml toluene treatment was used after each TiCl 4 /toluene reaction step. Analysis of the solid catalyst component showed it to contain 17 wt % Mg and 2.9 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 1, except that 40 ml of toluene and 60 ml of TiCl 4 were used in each reaction step. Analysis of the solid catalyst component showed it to contain 20 wt % Mg and 1.2 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 1, except that 60 ml of toluene and 40 ml of TiCl 4 were used in each reaction step. Analysis of the solid catalyst component showed it to contain 20 wt % Mg and 1.5 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• Example 9 An aliquot of the catalyst slurry prepared in Example 9 was dried under vacuum. The test procedure described in Example 1 was followed except that the dry catalyst is added to the 45 ml of hexane instead of a slurry. The results are found in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 3, except that the reactor was a 250 ml round bottom flask, and three series of TiCl 4 -toluene reactions and 1 ⁇ 100 toluene treatments are used. Analysis of the solid catalyst component showed it to contain 15 wt % Mg and 3.8 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 1, except that the reactor was a 250 ml round bottom flask, and three series of TiCl 4 -toluene reactions and 1 ⁇ 100 toluene treatments were used.
• Example 2 Following the procedure in Example 1, the supernatant was decanted, and two treatments with 100 ml of toluene each were carried out. The TiCl 4 +toluene reaction/toluene treatment step were repeated three additional times. The solids were then washed four times with 100 ml heptane each time. An additional 100 ml of heptane was added to the flask, the slurry was transferred to a vacuum filter apparatus, filtered and dried.
• a slurry of a solid catalyst component was prepared in then same manner as Example 14 with the exception that the di-isobutylphthalate was added at room temperature after the addition of the initial TiCl 4 charge. Analysis of the solid catalyst component showed it to contain 20 wt % Mg and 1.4 wt % Ti. Polymerization testing results, obtained under the same conditions as shown in Example 1, are found in Table 1, below.
• Example 15 A portion of the catalyst slurry obtained in Example 15 was filtered and vacuum dried.
• Table 1 contains the polymerization test results for this catalyst, carried out under the conditions of Example 1, modified for the use of dry catalyst as in Example 11. The results of this Example are not illustrated in Table 1.
• Example 1 The catalyst prepared in Example 1 was tested for polymerization performance as in Example 1, except that the test is run at 80° C. for one hour. The averaged results of two tests were as follows: activity, 132.6 kg/g catalyst; poured bulk density, 0.474 g/ml; total xylene insolubles, 99.37 wt %.
• Example 12 The procedure described in Example 12 was followed to produce a solid catalyst component except that 1.43 g of phthaloyl dichloride was substituted for diisobutyl-phthalate.
• Table 1 The results of polymerization testing using the procedure in Example 1, modified for the use of dry catalyst as in Example 11, are presented in Table 1, below.
• a catalyst preparation was carried out using the procedure described in Example 1, except that 40 ml of toluene and 10 ml of TiCl 4 were used in the reaction steps. Analysis of the solid catalyst component showed it to contain 22 wt % Mg and 0.69 wt % Ti. Testing was carried out as described in Example 1, and the results are shown in Table 1, below.
• Example 1-8 describe modes for preparing the catalyst along with the effects of varying the TiCl 4 /toluene ratio and number and volume of toluene treatments.
• Example 1 versus Example 9, and Example 3 and 7 versus Example 10 show the benefit of reducing the volume of the TiCl 4 /toluene reaction mixture from 10 ml/g support precursor (Examples 9 and 10) to 5 ml/g support precursor (Examples 1, 3, and 7).
• Example 9 versus Example 11 illustrates the improvement in catalyst performance when the catalyst is not dried and is isolated as a slurry versus isolation as a dry powder.
• Example 3 versus 12 and Example 6 versus 13 exhibit the difference found for carrying out four versus three treatment cycles.
• Example 9 versus Example 15 compares the effects of the temperature of addition of the diisobutylphthalate (DIBP) internal donor, 70° C. versus room temperature, for catalysts isolated as slurries (room temperature, higher activity).
• DIBP diisobutylphthalate
• Examples 14, 11, and 16 show the effect of the temperature of addition of the DIBP internal donor, 90° C. versus 70° C. versus room temperature, for catalysts isolated as dry powders (room temperature, higher activity).
• Example 17 shows the increase in activity achieved when the polymerization test is run at 80° C. instead of 70° C.
• Example 18 which is best compared to Example 11 that used a mixed phase ClMg(OEt) support precursor, shows the present invention using, as a starting reagent, a pure phase ClMg(OEt) material.
• the activity of the catalyst was almost 50% greater than that for the mixed phase support material.
• Example 14 versus Comparative Example 1 shows the use of a phthalate ester, DIBP in this case, gives a superior catalyst to the use of the corresponding acid chloride, phthaloyl dichloride, when ClMg(OEt) is the support precursor (dry catalyst).
• Comparative Example 2 versus Examples 1-4 shows that reducing the volume % of TiCl 4 in the TiCl 4 /toluene reaction mixture from 40% to 20% causes a large loss in activity, not evident from the trend found in the 80%-40% range.

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