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
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
  • C08F4/652—Pretreating with metals or metal-containing compounds
  • C08F4/654—Pretreating with metals or metal-containing compounds with magnesium or compounds thereof
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
  • Y10S526/905—Polymerization in presence of transition metal containing catalyst in presence of hydrogen
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
  • Y10S526/907—Specified means of reacting components of transition metal catalyst

Definitions

• the invention relates to a process for the homo- or copolymer ⁇ ization of olefins by contacting one or more polymerizable olefins having the general formula
• R- j _ and R 2 are the same or different and are hydrogen or a c l" c 10 alk Yl/ with a polymerization catalyst system obtained by contacting at least the following components:
• the invention also relates to a catalyst component intended for the polymerization of one or several olefins having the general formula
• R and R 2 are the same or different and are hydrogen or a c l ⁇ c 10 a lkY-L and which has been prepared by contacting at least the following components:
• the invention also relates to the use of a catalyst component of the above type for the polymerization of one or more olefins according to Formula (I) given above.
• Olefins are commonly polymerized using a Ziegler-Natta catalyst system which comprises a so-called procatalyst and a so-called cocatalyst.
• the procatalyst is in the catalyst system that component which is based on a compound of a transition metal belonging any of Groups 4-10 of the Periodic Table of the Ele ⁇ ments (IUPAC 1990), such as titanium, vanadium, chromium or zirconium.
• a typical procatalyst is made up of a titanium halide compound supported on a magnesium halide.
• the cocatalyst for its part is in the catalyst system that component which is based on an organometallic compound of a metal belonging to any of groups 1-3 and 13 of the Periodic Table of the Elements (IUPAC 1990), such as a metal hydride or a metal alkyl.
• a typi ⁇ cal cocatalyst is an alkylaluminum compound.
• the catalyst system in addition to a procatalyst (including the support) and a cocat ⁇ alyst, the catalyst system usually also includes agents which enhance and modify the catalytic properties, such as electron donor compounds and other auxiliaries.
• the function of the electron donors is to control the stereospecificity of the polymer and, when necessary, to improve the activity of the catalyst system.
• a large number of electron donors are known in the art, and they include ethers, esters and polysilanes or siloxanes.
• the activity and stereospecificity of the catalyst system, as well as the other properties of the polymer formed, such as its morphology and bulk density, can be af ⁇ fected by contacting the procatalyst and the cocatalyst, and any electron donors and other additives, before the catalyst system is used for the polymerization of an olefin or olefins.
• the said components of the catalyst system have been contacted outside the polymerization reaction zone and been subsequently fed into the polymerization zone and con ⁇ tacted therein with the olefin(s) in polymerization conditions.
• such contacting before polymerization can be carried out either before the so-called prepolymerization, or after it. In prepolymerization the particles of the catalyst system are surrounded with a small amount of polymer before they are fed into the actual polymerization zone.
• EP-588 277 A2 discloses a precontacting process in which a procatalyst prepolymerized by using a small amount of a monomer and a cocatalyst is contacted with a cocatalyst and an external electron donor before being introduced into the poly ⁇ merization reaction zone.
• the pretreated procatalyst is contacted with the cocatalyst as the procatalyst is being fed into a dilute stream of cocata ⁇ lyst; this stream carries the procatalyst into the polymeriza ⁇ tion zone.
• the preferred con ⁇ centration of cocatalyst in the stream is within a range of 10- 30 % by weight.
• the publication further teaches that the more cocatalyst is contacted with the procatalyst before the stream of procatalyst and cocatalyst enters the polymer reaction zone, the higher is the efficiency of the catalyst (cf. page 5, lines 8-13, of said publication).
• EP-517 183 A2 discloses the activation of procat ⁇ alyst in olefin polymerizations in a gas phase reactor.
• all of the procatalyst, cocatalyst and external electron donor is introduced into the precontacting vessel, in which the activation of the procatalyst is carried out and an active catalyst system is obtained.
• an n-hexane solution of triethyl aluminum (TEA) and cyclohexyl methyl dimethoxy silane, the latter serving as the external donor are added into the precontacting vessel in an amount such that the molar ratio of TEA/Ti is greater than 1 and usually within a range of 20-800 (cf.
• the object of the present invention is to provide an olefin polymerization process and a catalyst component which is usable in the olefin polymerization process and produces a maximal amount of polyolefin.
• a further object is a maximally pure polyolefin, i.e. a polyolefin having a minimal ash content. The ash mostly consists of inorganic catalyst residue remaining in the polyolefin.
• the invention also aims at a maximally high stereospecificity when what is in question is the polymeriza ⁇ tion of olefins containing at least 3 carbon atoms.
• the inven ⁇ tion also aims at as good a polyolefin morphology as possible, i.e. a preferred form, size, and size distribution of the formed polyolefin particles.
• a particular aim in this case is the minimization of the amount of fines in the polyolefin product.
• procatalysts and cocatalysts of different types it is possible to add procatalysts and cocatalysts of different types to the different steps. It is, however, preferable to use only one type of procatalyst and/or only one type of cocata ⁇ lyst. It is especially preferable to introduce the entire pro ⁇ catalyst amount of the process into the precontacting step a), where it is, in the manner described above, contacted with the cocatalyst so that the molar ratio Al/Ti is within a range of 0.1-20.
• the cocatalyst to be fed into the polymerization zone is divided into at least two portions.
• the first portion i.e. the first amount of cocat ⁇ alyst
• the mixing is preferably carried out in a so-called precontacting zone.
• the cocatalyst amount must be controlled so that the molar ratio Al/Ti is within a range of 0.1-20.
• a prefer ⁇ able molar ratio Al/Ti is, however, within a range of 0.5-16, and an even more preferable molar ratio within a range of 1.0- 8.0, and the most preferable molar ratio within a range of approx. 1.5-5.0.
• the first cocatalyst amount, used in step a) of the process preferably constitutes 0.1-30 % by weight, more preferably 0.5-10 % by weight, and most preferably 1.0- 5.0 % by weight of the total amount of cocatalyst used in the process.
• the rest of the cocatalyst needed is introduced after step a) into one or more pre-, homo- or co ⁇ polymerization steps b) and c).
• step a) a first amount of cocatalyst, at least one half of the total amount of procatalyst, and a first amount of external electron donor (ED) are contacted in the absence of polymerizable olefin, preferably so that the molar ratio Al/ED is within a range of 0.5-100, in order to obtain a precontact product.
• step b) this precontact product, a sec ⁇ ond amount of cocatalyst, a second amount of external electron donor (ED), and one or more polymerizable olefins are contacted in order to obtain a first homo- or copolymerization product or, alternatively, a prepolymerization product.
• a pre ⁇ polymerization product is prepared, i.e. prepolymerization is carried out using the catalyst system
• step c) it is possible in step c) to contact the prepolymerization product, a third amount of cocatalyst, a third amount of external electron donor (ED), and one or more polymerizable olefins according to Formula (I) in order to produce a second homo- or copolymerization product.
• the first homo- or copolymerization product, the pre ⁇ polymerization product or the second homo- or copolymerization product is recovered in step d) .
• step a) the first amount of cocata- lyst, at least one-half of the total amount of procatalyst, and the first amount of external electron donor (ED) are contacted in such amounts that the molar ratio Al/ED is within a range of 1.0-50, preferably 1.0-20.
• the yield of the olefin polymerization catalyst system and the quality of the polyolefin prepared using it are improved if the procatalyst is precontacted with a small amount of cocatalyst, possibly together with an external electron donor. Since the quality of the polyolefin is improved specifically so that the amount of fines present in it is crucially reduced, it can be concluded that by the precontacting according to the invention, by using a small amount of cocatalyst, it is possible to avoid the fragmentation of catalyst particles into fines, which is then repeated in the polymer product. By maintaining in the precontacting step a) the amounts and concentrations of the cocatalyst and the external electron donor, if any, at low values, the formation of detrimental fines in the catalyst and in the polyolefin product can thus be avoided.
• a low cocatalyst amount in the precontacting step a) also in ⁇ creases the activity of the catalyst system in the polymeriz ⁇ ation of olefins.
• the reason for this is not known with cer ⁇ tainty, but it is known that the cocatalyst tends to reduce the transition metal of the transition metal component, whereupon large amounts may excessively reduce the transition metal to a non-active form.
• small amounts and concen ⁇ trations of cocatalyst perform the reducing more delicately, in which case a larger proportion of the transition metal is ac ⁇ tivated.
• the precontacting step a) using an incomplete amount of cocat ⁇ alyst can be carried out in any suitable vessel equipped with mixing, but also in a pipe system or a static mixer.
• the structure of the mixer is not critical in terms of the pre ⁇ contacting step a).
• the temperature is also not critical, al ⁇ though preferably it is between -50 °C and +100 °C, more pref ⁇ erably between -20 °C and +50 °C, and most preferably between -5 °C and +30 °C
• a solution of cocatalyst and possib ⁇ ly of donor is used, in which case, according to one embodi ⁇ ment, the solvent used is a Cg-C ⁇ 2 hydrocarbon preferably hav- ing a density of 0.6-0.9 g/cm , such as n-heptane.
• the contact period in the precontacting step is also not critical, and according to one embodiment it is within a range of 10 s - 5 h, preferably within a range of 10 min - 2 h.
• both a pure procatalyst and a procatalyst which has been coated with a prepolymer by prepolymerization can be used in step a) .
• a procatalyst which is a procatalyst not coated with prepolymer since in such a case the attenuating effect of a small cocatalyst amount on the contacting reaction will be high, and a cumbersome and expen- sive prepolymerization treatment is not needed, i.e. a partial precontacting replaces prepolymerization.
• the present process for the homo- or copolymerization of ole ⁇ fins comprises, in addition to the precontacting step a) men ⁇ tioned above, also at least one polymerization step.
• the pre ⁇ contacting step a) is followed by a polymerization step b) , in which the product of the precontacting step, a second amount of cocatalyst, and one or more polymerizable olefins according to Formula (I) are contacted in order to produce a first homo- or copolymerization product or, alternatively, a prepolymerization product.
• the polymerization step b) following the precontacting step a) may thus lead either to a first completed homo- or co ⁇ polymerization product or alternatively to a prepolymerization product.
• these alternatives have in common the fact that, owing to the precontacting step, polymerization is more ample and yields polyolefin of a better quality.
• prepolymerization product i.e. a procatalyst coated with a small amount of polymer
• this coated procatalyst may, in a second, subsequent polymerization step c) be con ⁇ tacted with a third amount of cocatalyst, with one or more polymerizable olefins according to Formula (I) and possibly with a third amount of external electron donor to produce a second homo- or copolymerization product.
• molar ratio Al/Ti which is normal in the polymerization of olefins by using a catalyst system which contains titanium and aluminum.
• the molar ratio Al/Ti is in this case meant the total molar ratio, i.e. the amounts introduced in steps a), b) and possibly c) are included in the calculation of the aluminum and titanium amounts.
• a typical total molar ratio Al/Ti is within a range of approx. 50-1500.
• R ] _ and R 2 are the same or different and are hydrogen or a c l ⁇ c 10 alk Y!-
• olefins include ethylene, propylene, 1- butene, isobutene and 4-methyl-l-pentene.
• Some examples of usable higher olefins are 1-pentene, 3-methyl-1-butene, 4- methyl-1-hexene, 5-methyl-l-hexene, 5-methyl-l-heptene, vinyl- cyclohexane, and 1-decene.
• the process according to the invention concerns both the mutual copolymerization of the said olefins and their copolymerization with other monomers which are capable of being polymerized by using a Ziegler-Natta catalyst system of the type in question. It is also to be borne in mind that, if several polymerization steps (b) and c)) are used, different monomers can be used in different steps. In the production of certain polyethylene types, it has proved useful to employ propylene for prepoly ⁇ merization.
• a poly ⁇ merizable olefin according to general formula (I) is contacted with a polymerization catalyst system which has been obtained by causing a procatalyst which contains titanium, chlorine and magnesium to react with a cocatalyst and possibly an external electron donor.
• the procatalyst which contains titanium, chlor ⁇ ine and magnesium preferably comprises a titanium compound which contains at least one titanium-halide bond, the compound being supported on an active magnesium compound.
• the titanium compound which contains a titanium-halide bond may be titanium tetrachloride, TiCl 4 , or titanium trichloride, TiCl 3 , prefer ⁇ ably titanium tetrachloride, TiCl 4 .
• the magnesium compound may be, for example, magnesium dichloride, MgCl 2 , magnesium alkyl MgR 2 or magnesium alkoxide Mg(OR) 2 where R is an alkyl.
• An especially preferable solid procatalyst usable in the process according to the invention comprises a titanium compound which contains at least one titanium-halide bond, the compound being supported on an active magnesium halide, preferably a reaction product of TiCl ⁇ and a MgCl 2 support.
• the polymerization catalyst system used in the process accord ⁇ ing to the invention is thus obtained by contacting a solid procatalyst with a cocatalyst which contains aluminum and a C- ⁇ - C 1Q alkyl, and possibly with an electron donor.
• the cocatalyst which contains aluminum and a C- ⁇ -C ⁇ Q alkyl is in this case preferably either aluminum halide, a mono-C ⁇ -C ⁇ Q -alkylaluminum dihalide, or any C 1 -C 1Q -alkylaluminum sesquihalide.
• alkylaluminum halides chlorine is a preferred halide.
• the most preferable cocatalyst for use in the process according to the invention is tri-C-_-C ⁇ Q -alkylaluminum, such as triethylaluminum (TEA). It should be pointed out that the cocatalyst may also be a mixture or reaction product of several compounds of the type mentioned above, containing alkyl and aluminum.
• TAA triethylaluminum
• a polymerization catalyst system which has been obtained by contacting a solid procatalyst, a cocatalyst and an external electron donor is used in the polymerization process.
• a solid procatalyst a cocatalyst and an external electron donor
• Electron donors usable in the process according to the invention include amines, amides, ethers, esters, ketones, nitriles, phosphines, stibines, arsines, phosporamides, thio- ethers, thioesters, aldehydes, alcoholates, amides, salts of organic acids, polysilanes, and siloxanes.
• preferred external electron donors to be mentioned are esters of carboxylic, alkoxy or amino acids, and esters of aromatic acids.
• Some examples to be mentioned of usable ethers include di-lower alkoxy alkanes, such as 2-ethyl-l,1-dimethoxyhexane (EDMH).
• Preferred external electron donors also include organic silicon compounds (silanes), such as diphenyldimethoxy silane (DPDMS), eyelohexylmethyldimethoxysilane (CHMMS), dicyclo- pentyldimethoxysilane (DCPDMS) and methyl-t-butyldimethoxy- silane (-TTBDMS).
• DDMS diphenyldimethoxy silane
• CHMMS eyelohexylmethyldimethoxysilane
• DCPDMS dicyclo- pentyldimethoxysilane
• -TTBDMS methyl-t-butyldimethoxy- silane
• the components used in the process according to the invention i.e. the solid procatalyst, the first, second and possibly third amounts of cocatalyst, the first, second and possibly third amounts of a possible external electron donor, the amount of one or more polymerizable olefins according to the general Formula (I) , and the amount of hydrogen can be contacted in any order within the framework of the steps a) - c) described above, except that in general the external donor is not con ⁇ tacted with the solid procatalyst before it is contacted with the cocatalyst. It has namely been observed that, alone, the external donor tends to poison the solid procatalyst.
• the procedure in the invention may be, for example, as follows:
• the cocatalyst and the external donor are mixed to ⁇ gether, the mixture is divided into two portions, one of which is precontacted with the solid procatalyst, and the obtained mixture is fed into the polymerization zone, and the other portion is fed directly into the polymerization zone, into which there is also fed the olefin, and possibly hydrogen.
• a portion of the cocatalyst is mixed with an internal donor, and the obtained mixture is divided into two portions, one of which is mixed with the solid procatalyst, and the thus obtained second mixture is fed into the polymerization zone, and the other portion is fed directly into the polymerization zone, into which there are also fed the remaining portion of the cocatalyst, the olefin, and possibly hydrogen.
• a portion of the cocatalyst is mixed together with the external electron donor, and the obtained mixture is mixed together with the solid procatalyst, whereafter the obtained mixture is fed into the polymerization zone, into which there are fed at the same time the remaining portion of the cocat ⁇ alyst, the olefin, and possibly hydrogen.
• a portion of the cocatalyst is mixed with both external electron donor and the solid procatalyst, and this mixture is then fed into the polymerization zone. At the same time another portion of the cocatalyst is mixed with electron donor, and the obtained mixture is also fed into the polymerization zone, into which there is also fed the olefin, and possibly hydrogen.
• a first portion of the cocatalyst is mixed with a solid procatalyst, and the obtained mixture is fed into the polymer ⁇ ization zone.
• a second portion of the cocat ⁇ alyst and the electron donor are fed separately into the poly ⁇ merization zone, into which there is also fed the olefin, and possibly hydrogen.
• a first portion of the cocatalyst is mixed with the solid procatalyst, and the obtained mixture is fed into the polymerization zone.
• a second portion of the cocatalyst is mixed with the external electron donor and is fed directly into the polymerization zone, into which there is also fed the ole ⁇ fin monomer, and possibly hydrogen.
• a portion of the cocatalyst is mixed with the external electron donor and the solid procatalyst, and the obtained mix ⁇ ture is fed into the polymerization zone.
• a second portion of the cocatalyst is fed directly into the reac ⁇ tion zone, into which there is also fed the olefin monomer, and possibly hydrogen.
• a first portion of the cocatalyst is mixed with a first portion of the external electron donor and with the solid pro ⁇ catalyst, and the obtained mixture is fed into the polymeriza ⁇ tion zone.
• a second portion of the cocatalyst and a second portion of the external electron donor are fed directly into the polymerization zone, into which there is also fed the olefin monomer, and possibly hydrogen.
• the invention also relates to a catalyst component intended for the polymer ⁇ ization of one of several olefins having the general formula
• R ⁇ and R 2 are the same or different and are hydrogen or a C-i-C-.g alkyl and which has been prepared by contacting at least the following components:
• the catalyst component according to the invention is mainly characterized in that in its preparation, in the absence of polymerizable olefin, the cocatalyst and the procatalyst are contacted so that the molar ratio Al/Ti is within a range of 0.1-20.
• the catalyst component which is an object of the invention corresponds to the precontacting product of step a) of the process according to the invention for the homo- or copolymerization of olefins.
• any specifi ⁇ cations, limitations and embodiments relating to the catalyst component according to the invention are substantially the same as the specifications, limitations and embodiments relating to the catalyst component, as stated in Claims 3, 4, 6-12, and 16- 18.
• the invention also relates to the use of a catalyst component according to Claim 20 for the homo- or copolymeriza ⁇ tion of one or several olefins according to Formula (I).
• the use is mainly characterized in what is stated in the characterizing clause of Claim 21.
• the procedure is as follows: ( ⁇ ) the said catalyst component, an additional amount of cocatalyst, and one or more polymerizable olefins according to Formula (I) are contacted to produce a first homo- or copoly ⁇ merization product or, alternatively, a prepolymerization prod ⁇ uct;
• steps ( ⁇ )-( ⁇ ) of the use according to the invention correspond to steps b) - d) of the homo- or copoly ⁇ merization process described above.
• steps ( ⁇ )-( ⁇ ) of the use according to the invention correspond to steps b) - d) of the homo- or copoly ⁇ merization process described above.
• the storage containers for the external electron donor, the cocatalyst and the procatalyst are indicated respectively by numerals 1, 2 and 3.
• the precontacting vessel is indicated by numeral 4.
• the prepolymerization reactor is indicated by numeral 5.
• the process equipment operates as follows: The components of the cocatalyst system are introduced into the precontacting vessel 4 in the manner shown in the figure.
• the catalyst ac ⁇ tivated by means of precontacting is then introduced via pipe A into the prepolymerization reactor.
• the procatalyst, the cocat ⁇ alyst and the electron donor may be introduced either in pure form or diluted with a suitable inert solvent.
• the procatalyst and the activated procatalyst may be added by any method, either continuously or in batches.
• the amount of the cocatalyst and the external donor required for the polymerization is divided into two portions.
• the amount required for the precontacting is introduced via line A and the amount required directly in the prepolymerization or the poly ⁇ merization is fed separately into the prepolymerization or polymerization reactor via line B.
• the activated catalyst com ⁇ ponent prepared by the precontacting according to the present invention can be used in slurry, solution, gas phase or solvent-free liquid phase polymerization.
• the process according to the invention can be used in continuous polymerization, in semi-batch or batch polymerization, or in polymerization requiring the prepolymerization mentioned above.
• the said activation by means of precontacting can alternatively be carried out in a so-called CSTR reactor, a pipe, or a static mixer.
• the precontacting vessel in which the activation takes place may be pressurized or be maintained at ambient pressure.
• the prepolymerization and/or polymerization zone in the process according to the invention may alternatively consist of one or more reactors.
• the prepolymerization or polymerization may alternatively be carried out as a batch, semi-batch or con ⁇ tinuous gas-phase, bulk or slurry polymerization.
• the cocatalyst used in the examples was triethyl aluminum (TEA).
• the external electron donor was cyclohexyl methyl di ⁇ methoxy silane (CHMMS) in Examples 1-3, dicyclopentyl dimethoxy silane (DCPDMS) in Examples 4-6, and 2-ethyl-l,l-dimethoxy hexane (EDMH) in Examples 7-9.
• the procatalyst was a high-yield
• the titanium content of the procatalyst was 2.4 % by weight.
• the procatalyst was diluted in an inert heavy hydrocarbon solvent (density 0.900 g/cm at 20 °C) .
• the concentration of procatalyst was 175 g procatalyst/liter cata ⁇ lyst slurry.
• melt flow rates (abbreviated MFR 2>16 , ISO 1133:1991E) of the polymer were measured at 230 °C by using a weight of 2.16 kg for the extrusion.
• the isotacticity indices (I.I.) were determined by n-heptane extraction.
• Example 1 the concentrations of the cocatalyst and the external electron donor were minimized, but the Al/Ti molar ratio was relatively high. This means that the cocatalyst and the external electron donor were diluted to very low con ⁇ centrations. In Examples 2, 5 and 8, the concentrations of cocatalyst and external electron donor were the second lowest, while the Al/Ti molar ratio was very low.
• the catalyst was activated in a different way in each example, but the final concentrations of catalyst, cocatalyst and ex ⁇ ternal electron donor were the same in all examples.
• the poly ⁇ merization conditions and the results obtained are shown in Tables 1, 2 and 3. Polymerizations
• TEA triethyl aluminum
• CHMMS cyclohexyl methyl dimethoxy silane
• TEA 260 ⁇ l of TEA was mixed with 19 ⁇ l of CHMMS in 15 ml of n- heptane. Thereafter the mixture of TEA and CHMMS was introduced into a 20.2 mg portion of procatalyst. Thereafter the mixture of TEA, CHMMS and procatalyst was transferred into a 5-liter stainless steel autoclave. Precontacting was carried out at room temperature. After the precontacting step this mixture was also transferred into the reactor.
• the activity of the catalyst system was 29.8 kg/g procatalyst. According to an n-heptane extraction test, the isotacticity index was 97.0 % by weight.
• the MFR 2 - j _6 °f tne polymer was 8.0 g/10 min.
• the polymer con ⁇ tained 0.5 % by weight particles having a size smaller than 0.5 mm.
• TEA 690 ⁇ l of TEA was added to 50 ⁇ l of CHMMS in 10 ml of n-heptane at room temperature. Thereafter the mixture of TEA and silane was transferred into the reactor.
• TEA 1720 ⁇ l of TEA was mixed with 503 ⁇ l of CHMMS. Thereafter the mixture of TEA and CHMMS was added to 25.70 g of a procatalyst slurry (containing 5.0 mg of dry procatalyst) at room tempera ⁇ ture. 106.3 mg of the TEA, CHMMS and procatalyst mixture, con ⁇ taining 19.25 mg of dry procatalyst, was transferred into the reactor by using 10 ml of n-heptane.
• Example 2 Polymerization was carried out in the same conditions as in Example 1.
• the activity of the catalyst system was 25.4 kg/g procatalyst.
• the I.I. was 96.3 % by weight.
• the MFR 2 - ⁇ g was 8.2 g/10 min.
• the polymer contained 2.4 % by weight particles having a size smaller than 0.5 mm.
• TEA 5540 ⁇ l of TEA was mixed with 2340 ⁇ l of CHMMS (50 % by volume, diluted in n-heptane). Thereafter the mixture of TEA and CHMMS was added to 2.56 g of a procatalyst slurry (containing 0.5 g of dry procatalyst) at room temperature. 363.3 mg of the TEA, CHMMS and procatalyst mixture, containing 19.95 mg of dry pro ⁇ catalyst, was transferred into the reactor by using 10 ml of n- heptane.
• Example 4 (comparative)
• TEA 431 ⁇ l of TEA was mixed with 36 ⁇ l of dicyclopentyl dimethoxy silane (DCPDMS) in 25 ml of n-heptane at room temperature. The mixture of TEA and silane was transferred into the reactor.
• DCPDMS dicyclopentyl dimethoxy silane
• TEA 258 ⁇ l of TEA was mixed with 22 ⁇ l of DCPDMS in 15 ml of n- heptane. Thereafter the mixture of TEA and DCPDMS was added to a 20.1 mg portion of procatalyst. Thereafter the mixture of TEA, DCPDMS and procatalyst was transferred into a 5-liter stainless steel autoclave. Activation by precontacting was also carried out at room temperature. Thereafter this mixture was also transferred into the reactor.
• the activity of the catalyst system was 29.0 kg/g procatalyst. According to an n-heptane extraction test, the I.I. was 98.3 % by weight.
• the MF 2.16 of the polymer obtained was 2.0 g/10 min.
• the polymer contained 0.3 % by weight particles having a size smaller than 0.5 mm.
• TEA 1029 ⁇ l of TEA was mixed with 580 ⁇ l of DCPDMS. Thereafter the mixture of TEA and DCPDMS was added to 25.72 g of a procatalyst slurry (containing 5.0 g of dry procatalyst) at room tempera- ture. 108.3 mg of the TEA, DCPDMS and procatalyst mixture, con ⁇ taining 19.95 mg of dry procatalyst, was transferred into the reactor by using 10 ml of n-heptane.
• Example 4 Polymerization was carried out in the same conditions as in Example 4.
• the activity of the catalyst system was 27.3 kg/g procatalyst.
• the I.I. was 98.3 % by weight.
• the MFR 2 ⁇ 6 was 2.1 g/10 min.
• the polymer contained 0.6 % by weight particles having a size smaller than 0.5 mm (diameter).
• TEA 5540 ⁇ l of TEA was mixed with 2230 ⁇ l of DCPDMS (50 % by vol ⁇ ume, diluted in n-heptane). Thereafter the mixture of TEA and DCPDMS was added to 2.572 g of a procatalyst slurry (containing 0.5 g of dry procatalyst) at room temperature. 362.1 mg of the TEA, DCPDMS and procatalyst mixture, containing 20 mg of dry procatalyst, was transferred into the reactor by using 10 ml of n-heptane.
• Example 4 Polymerization was carried out in the same conditions as in Example 4.
• the activity of the catalyst system was 13.8 kg/g procatalyst.
• the I.I. was 97.9 % by weight.
• the MFR 2>16 was 2.3 g/10 min.
• the polymer contained 16.9 % by weight particles having a size smaller than 0.5 mm.
• TEA 2-ethyl-l,1-dimethoxy hexane
• EDMH 2-ethyl-l,1-dimethoxy hexane
• the mixture of TEA and EDMH was transferred into the reactor.
• 258 ⁇ l of TEA was mixed with 22 ⁇ l of EDMH in 15 ml of n- heptane.
• the mixture of TEA and EDMH was added to 20.1 mg of procatalyst.
• the mixture of TEA, EDMH and procatalyst was transferred into a 5-liter stainless steel autoclave. Activation of procatalyst by precontacting was also carried out at room temperature. Thereafter the precontact product was transferred into the reactor.
• the activity of the catalyst system was 30.8 kg/g procatalyst. According to an n-heptane extraction test, the I.I. was 89.9 % by weight.
• the MFR 2>16 was 28.6 g/10 min.
• the polymer contained 0.4 % by weight particles having a size smaller than 0.5 mm.
• TEA 690 ⁇ l of TEA was added to 60 ⁇ l of EDMH in 10 ml of n-heptane at room temperature. Thereafter the mixture of TEA and EDMH was transferred into the reactor.
• TEA 1715 ⁇ l of TEA was mixed with 513 ⁇ l of EDMH. Thereafter the mixture of TEA and EDMH was added to 25.70 g of a procatalyst slurry (containing 5.0 g of dry procatalyst) at room tempera ⁇ ture. 110.3 mg of the TEA, EDMH and procatalyst mixture, con ⁇ taining 20 mg of dry procatalyst, was transferred into the reactor by using 10 ml of n-heptane.
• Example 7 Polymerization was carried out in the same conditions as in Example 7.
• the activity of the catalyst system was 27.3 kg/g procatalyst.
• the I.I. was 89.6 % by weight.
• the MFR 2> ⁇ g was 28.3 g/10 min.
• the polymer contained 3.2 % by weight particles having a size smaller " than 0.5 mm.
• TEA 5540 ⁇ l of TEA was mixed with 2594 ⁇ l of EDMH (50 % by volume, diluted in n-heptane). Thereafter the mixture of TEA and EDMH was added to 2.57 g of a procatalyst slurry (containing 0.5 g of dry procatalyst) at room temperature. 367 milligrams of the TEA, EDMH and procatalyst mixture, containing 19.85 mg of dry (calculated as dry) procatalyst, was transferred into the re ⁇ actor by using 10 ml of n-heptane.
• Example 7 Polymerization was carried out in the same conditions as in Example 7.
• the activity of the catalyst system was 14.7 kg/g procatalyst.
• the I.I. was 84.3 % by weight.
• the MFR 2>1 g was 32.9 g/10 min.
• the polymer contained 13.5 % by weight particles having a size smaller than 0.5 mm.
• Polymerization time was 1 hour.

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