WO2006087170A1 - Process for preparing ethylene (co) polymers - Google Patents

Process for preparing ethylene (co) polymers Download PDF

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Publication number
WO2006087170A1
WO2006087170A1 PCT/EP2006/001343 EP2006001343W WO2006087170A1 WO 2006087170 A1 WO2006087170 A1 WO 2006087170A1 EP 2006001343 W EP2006001343 W EP 2006001343W WO 2006087170 A1 WO2006087170 A1 WO 2006087170A1
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WO
WIPO (PCT)
Prior art keywords
polymerization
suspension
alkyl radical
ethylene
temperature
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PCT/EP2006/001343
Other languages
French (fr)
Inventor
Friedhelm Gundert
Maria Schmitt
Martin Schneider
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Basell Polyolefine Gmbh
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Publication date
Application filed by Basell Polyolefine Gmbh filed Critical Basell Polyolefine Gmbh
Priority to ES06723041.7T priority Critical patent/ES2487900T3/en
Priority to EP06723041.7A priority patent/EP1856163B1/en
Priority to CN2006800048790A priority patent/CN101120025B/en
Priority to BRPI0606925A priority patent/BRPI0606925B1/en
Priority to JP2007555520A priority patent/JP4916454B2/en
Priority to US11/884,505 priority patent/US7759445B2/en
Publication of WO2006087170A1 publication Critical patent/WO2006087170A1/en

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    • 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
    • C08F10/02—Ethene
    • 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
    • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/02—Ethene
    • 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
    • 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
    • C08F110/02—Ethene

Definitions

  • the invention relates to a process for the (co)poly ⁇ nerization of 1 -olefins to form polymer powder in the presence of catalyst systems of the Ziegler-Natta type which comprise a component A which is obtained by reaction of magnesium alkoxide with a titanium compound and an after-treatment of the reaction product and an organometallic compound of groups l-lll of the Periodic Table as component B.
  • catalyst systems of the Ziegler-Natta type which comprise a component A which is obtained by reaction of magnesium alkoxide with a titanium compound and an after-treatment of the reaction product and an organometallic compound of groups l-lll of the Periodic Table as component B.
  • EP-A 068 257 discloses a process for preparing Ziegler catalysts which are obtained from the reaction product of magnesium alkoxide with titanium tetrachloride as component A and an organometallic compound as component B.
  • the magnesium alkoxide is reacted with the titanium tetrachloride in a first reaction step at temperatures in the range from 50 to 100 0 C.
  • the reaction product is then after-treated thermally in a second reaction step at an elevated temperature in the range from 110 to 200 0 C until no further elimination of alkyl chloride occurs.
  • the polymers prepared using these catalysts have a broad molecular weight distribution.
  • EP-A 401 776 discloses a process for preparing a Ziegler catalyst in which the reaction product of magnesium alkoxide and titanium tetrachloride is firstly washed a number of times and then after-treated thermally for a period of 18 hours. These catalysts, too, give polymers having a broad molecular weight distribution.
  • This object is achieved by a process in which the component A is formed by allowing magnesium alkoxide to react with a transition metal compound, in particular a titanium compound, in a suspension medium and then subjecting the reaction product without further intermediate steps to a thermal after-treatment for a period of not more than 120 minutes.
  • a transition metal compound in particular a titanium compound
  • R 1 and R 2 are identical and are each an unbranched or branched alkyl radical having from 1 to 20 carbon atoms or a radical (CH 2 ) n OR 3 , where R 3 is an alkyl radical having from 1 to 4 carbon atoms and n is an integer from 2 to 6, is initially charged in a suspension medium and reacted with a tetravalent transition metal compound of the formula Il
  • M 1 is titanium, zirconium or hafnium
  • R 4 is an alkyl radical having from 1 to 9 carbon atoms and X is a halogen atom and m is an integer from zero to 4, at a temperature in the range from 20 to 140 0 C and the reaction product is then after- treated thermally at a temperature in the range from 90 to 200 0 C for a period of from 10 to 180 minutes.
  • the preparation of the mixed catalyst component to be used according to the invention is carried out using a magnesium alkoxide of the formula (I)
  • R 1 and R 2 are identical or different and are each an unbranched or branched alkyl radical which preferably has from 2 to 10 carbon atoms or a radical -(CH 2 )nOR 6 , where R 6 is a Ci-C 4 -alkyl radical, preferably a Ci-C 2 -alkyl radical, and n is an integer from 2 to 6.
  • magnesium alkoxides such as magnesium diethoxide, magnesium di-n-propoxide and magnesium di-i-butoxide.
  • the magnesium alkoxide is used as a suspension or as a gel dispersion.
  • the magnesium alkoxide is firstly reacted with a tetravalent transition metal compound of the formula Il
  • M 1 is titanium, zirconium or hafnium, preferably titanium or zirconium
  • R 3 is an alkyl radical having from 1 to 9, preferably from 1 to 4 carbon atoms
  • X is a halogen atom, preferably chlorine
  • m is from zero to 4, preferably from 2 to 4.
  • TiCI 4 TiCI 3 (OC 2 H 5 ), TiCI 2 (OC 2 Hg) 2 , TiCI(OC 2 Hs) 3 , Ti(OC 2 Hg) 4 , TiCI 3 (OC 3 H 7 ),
  • the reaction of the magnesium alkoxide with the tetravalent transition metal compounds is carried out at a temperature at from 20 to 140 0 C, preferably from 60 to 90 0 C, over a period of from 1 to 20 hours.
  • Suitable inert suspension media for the abovementioned reactions include aliphatic and cycloaliphatic hydrocarbons such as butane, pentane, hexane, heptane, cyclohexane, isooctane and also aromatic hydrocarbons such as benzene and xylene. Petroleum spirit and hydrogenated diesel oil fractions which have carefully been freed of oxygen, sulfur compounds and moisture can also be used.
  • the magnesium alkoxide and the tetravalent transition metal compound (M 1 ) are reacted in a molar ratio of Mg:M 1 of 1 :0.05 - 10, preferably 1 :0.1 - 3.5.
  • the suspension of the solid is stirred at from 90 to 200 0 C, preferably from 100 to 14O 0 C, for from 20 to 180 minutes, preferably from 30 to 90 minutes, and then washed until the supernatant mother liquor has Cl and Ti (Zr 1 Hf) concentrations of less than 10 mmol/l.
  • catalyst component B use is made of a trialkylaluminum having from 1 to 6 carbon atoms in the alkyl radical, e.g.
  • the mixing of the component A and the component B can be carried out in a stirred vessel at a temperature of from -3O 0 C to 15O 0 C prior to the polymerization. It is also possible to combine the two components directly in the polymerization vessel at a polymerization temperature of from 20 0 C to 200 0 C. However, the addition of the component B can also be carried out in two steps by preactivating the component A with part of the component B at a temperature of from -30 0 C to 150 0 C prior to the polymerization reaction and adding the remainder of the component B in the polymerization reactor at a temperature of from 20 0 C to 200 0 C.
  • the polymerization is carried out in one or more stages, preferably as a suspension polymerization, in an inert suspension medium.
  • Suitable suspension media are the same organic solvents as have been described for the preparation of the catalyst component A.
  • polymerization in the gas phase is also possible.
  • the polymerization temperature is from 20 to 120°C, preferably from 70 to 9O 0 C, and the pressure is in the range from 0.2 to 6.0 MPa, preferably from 0.4 to 2.0 MPa.
  • the ratio of the polyolefins of differing molar mass formed in the stages 1 and 2 is in the range from 30:70 to 70:30.
  • R 7 is a straight-chain or branched alkyl radical having from 1 to 12, preferably fom 1 to 10, carbon atoms.
  • Examples are propylen, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1- pentene. Preference is given to using propylene, 1-butene and 1-hexene.
  • the comonomer is preferably introduced in the second stage in which a polymer having the higher molar mass is formed.
  • the total polymer after the second stage is separated off from the dispersion medium and dried in a known manner.
  • Characteristics of the catalyst component A are a reduced time requirement compared to the prior art and a significantly reduced energy consumption.
  • a further increase in the polymerization activity of the catalyst to a high level is astonishingly found. This was particularly surprising because the known Ziegler catalysts are themselves known for a high polymerization activity.
  • the particle size distribution of the polymer is very uniform.
  • the molar mass of the polyolefins is regulated efficiently by means of hydrogen in the presence of the catalyst used according to the invention.
  • the suspension was cooled to room temperature.
  • the preparation of the catalyst component A was carried out as described in Example 1 except that the mixture was heated at 120 0 C for 1 hour after the addition of TiCI 4 .
  • the solid was subsequently resuspended in fresh diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 17O 0 C) and after a stirring time of 15 minutes and subsequent complete settling of the solid, the supernatant liquid phase was taken off again. This washing procedure was repeated until the titanium concentration of the mother liquor was then 10 mmol/dm 3 . After the washing step was concluded, the suspension was cooled to room temperature. The molar ratio of the solid was:
  • Example 1 b The polymerization is carried out as described in Example 1 b), except that the catalyst component A prepared as described in Example 3a was introduced into the reactor in an amount corresponding to 0.03 mmol of titanium as a suspension diluted with diesel oil.
  • the results of the polymerization are shown below in Table 1.
  • the preparation of the catalyst component A was carried out by the method described in Example 2, except that the mixture was heated at 120 0 C for 4 hours.
  • the suspension was then cooled to room temperature.
  • the molar ratio of the solid was: Mg:Ti:CI « 1 :0.44:2.54.
  • Example 1 The polymerization is carried out as described in Example 1 , except that the catalyst component A prepared as described in Comparative Example 1 was introduced into the reactor in an amount corresponding to 0.04 mmol of titanium as a suspension diluted with diesel oil.
  • the results of the polymerization are shown below in Table 1.
  • the solid was subsequently resuspended in fresh diesel oil (hydrogenated petroleum Traction having a boiling range from 140 to 170 0 C) and after a stirring time of 15 minutes and subsequent complete settling of the solid, the supernatant liquid phase was taken off again. This washing procedure was repeated until the titanium concentration of the mother liquor was 40 - 50 mmol/dm 3 .
  • the suspension was subsequently heated at 12O 0 C for 18 hours.
  • the suspension was then cooled to room temperature.
  • the molar ratio of the solid was: Mg:Ti:CI « 1:0.32:2.22.
  • Example 1 The polymerization is carried out as described in Example 1 , except that the catalyst component A prepared as described in Comparative Example 2 was introduced into the reactor in an amount corresponding to 0.1 mmol of titanium as a suspension diluted with diesel oil.
  • the results of the polymerization are shown below in Table 1.
  • Table 1 Polymerization experiments in 1.5 dm 3 reactor, 2 mmol of triethylaluminum, 0.8 dm 3 of diesel oil, polymerization temperature: 85°C, 3.15 bar of H 2 , 3.85 bar of C 2 (total pressure: 7 bar), polymerization time: 2 h
  • the supernatant liquid phase (mother liquor) was then decanted off to a residual volume of 50 dm 3 .
  • the supernatant liquid was again decanted off to a residual volume of 50 dm 3 . This washing procedure was repeated until the titanium concentration of the mother liquor was less than 10 mmol/dm 3 .
  • the polymerization experiments were carried out batchwise in a 200 dm 3 reactor. This reactor was equipped with an impeller stirrer and baffles. The temperature in the reactor was measured and automatically kept constant. The polymerization temperature was 85 ⁇ 1 0 C.
  • the reactor was pressurized a number of times with H 2 (hydrogen) to 8 bar and depressurized again to remove the nitrogen completely from the reactor (the procedure was monitored by measurement of the H 2 concentration in the gas space of the reactor, which finally indicated 95% by volume).
  • the polymerization was started by opening the ethylene inlet. Ethylene was introduced in an amount of 8.0 kg/h over the entire polymerization time, with the pressure in the reactor rising slowly.
  • the polymerization was stopped after 225 minutes (total of 30 kg of ethylene gas fed in) and the total pressure was read off. The contents of the reactor were drained onto a filter. The polymer which was moist with diesel oil was dried in a stream of nitrogen over a period of several hours.
  • Example 6a The polymerization of ethylene over the prepolymerized catalyst component A was carried out by a method analogous to that described in Example 4b).
  • the dry catalyst described in Example 6a was resuspended in diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 170 0 C).
  • the suspension was cooled to room temperature.
  • the molar ratio of the solid was: Mg:Ti:CI « 1 :0.15:2.13.
  • the molar aluminum/titanium ratio was thus 20:1.

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  • Chemical Kinetics & Catalysis (AREA)
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  • Polymers & Plastics (AREA)
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Abstract

For the (co) polymerization of ethylene with other 1-olefins, a Ziegler catalyst which comprises the product from the reaction of a magnesium alkoxide suspended or dispersed as ge in an inert solvent with a tetravalent transition metal compound and is subjected to a thermal after-treatment for a period of not more than 180 minutes is prepared. The catalyst gives a high yield of a polymer powder which has a broad molar mass distribution and is best suited to the production of films, hollow bodies and pipes.

Description

Process for preparing 1 -olefin (co)polymers
The invention relates to a process for the (co)polyτnerization of 1 -olefins to form polymer powder in the presence of catalyst systems of the Ziegler-Natta type which comprise a component A which is obtained by reaction of magnesium alkoxide with a titanium compound and an after-treatment of the reaction product and an organometallic compound of groups l-lll of the Periodic Table as component B.
Processes for preparing polyolefins by means of catalysts formed by reaction of magnesium alkoxides with transition metal halides are known (DE-B 1 795 197). In this case, a temperature range from 0 to 2000C is recommended for the reaction, but the upper temperature limit should be selected so that no decomposition products are formed. Advantages are said to be not only the high activity of the polymerization catalysts but also, in particular, the possibility of preparing ethylene homopolymers and ethylene-α-olefin copolymers having a narrow molecular weight distribution.
EP-A 068 257 discloses a process for preparing Ziegler catalysts which are obtained from the reaction product of magnesium alkoxide with titanium tetrachloride as component A and an organometallic compound as component B. To prepare the component A, the magnesium alkoxide is reacted with the titanium tetrachloride in a first reaction step at temperatures in the range from 50 to 1000C. The reaction product is then after-treated thermally in a second reaction step at an elevated temperature in the range from 110 to 2000C until no further elimination of alkyl chloride occurs. The polymers prepared using these catalysts have a broad molecular weight distribution.
EP-A 401 776 discloses a process for preparing a Ziegler catalyst in which the reaction product of magnesium alkoxide and titanium tetrachloride is firstly washed a number of times and then after-treated thermally for a period of 18 hours. These catalysts, too, give polymers having a broad molecular weight distribution.
The known processes are time-consuming and require large amounts of energy, which under the pressures of scarce resources leads to competitive disadvantages and to more expensive end products. In addition, the known catalysts still leave something to be desired in respect of their polymerization activities.
It was an object of the invention to find a simple process for preparing Ziegler catalysts which make it possible to prepare polymers in high yields. These polymers should have a medium to broad molar mass distribution, expressed as Mw/Mn, of greater than 6.9 even in a single-stage polymerization process. This property makes these catalysts suitable for preparing polymer products having an excellent balance between processing behavior and final properties in a single-stage or multistage process. An example which may be mentioned is the preparation of polymer material which can be processed by film blowing with good parison stability to give films having particularly good mechanical properties, e.g. the dart drop value in accordance with ASTM D 1709.
This object is achieved by a process in which the component A is formed by allowing magnesium alkoxide to react with a transition metal compound, in particular a titanium compound, in a suspension medium and then subjecting the reaction product without further intermediate steps to a thermal after-treatment for a period of not more than 120 minutes.
The invention accordingly provides a process for preparing an olefin polymer by (co)polymerization of ethylene or of ethylene with up to 10% by weight, based on the total amount of monomers, of a 1 -olefin of the formula R-CH=CH2, where R is a straight-chain or branched alkyl radical having from 1 to 12 carbon atoms, in suspension, in solution or in the gas phase, at a temperature of from 20 to 1200C, and a pressure of from 0.2 to 6.0 MPa in the presence of a catalyst comprising the reaction product of a magnesium alkoxide with a tetravalent titanium compound, wherein a magnesium alkoxide of the formula I
Mg(OR1)(OR2) (I),
where R1 and R2 are identical and are each an unbranched or branched alkyl radical having from 1 to 20 carbon atoms or a radical (CH2)nOR3, where R3 is an alkyl radical having from 1 to 4 carbon atoms and n is an integer from 2 to 6, is initially charged in a suspension medium and reacted with a tetravalent transition metal compound of the formula Il
M1Xm(OR4)4-m (H),
where M1 is titanium, zirconium or hafnium, R4 is an alkyl radical having from 1 to 9 carbon atoms and X is a halogen atom and m is an integer from zero to 4, at a temperature in the range from 20 to 1400C and the reaction product is then after- treated thermally at a temperature in the range from 90 to 2000C for a period of from 10 to 180 minutes. The preparation of the mixed catalyst component to be used according to the invention is carried out using a magnesium alkoxide of the formula (I)
Mg(OR1)(OR2) (I).
In this formula, R1 and R2 are identical or different and are each an unbranched or branched alkyl radical which preferably has from 2 to 10 carbon atoms or a radical -(CH2)nOR6, where R6 is a Ci-C4-alkyl radical, preferably a Ci-C2-alkyl radical, and n is an integer from 2 to 6.
Examples of such magnesium alkoxides are:
magnesium dimethoxide, magnesium diethoxide, magnesium di-i-propoxide, magnesium di-n-propoxide, magnesium di-n-butoxide, magnesium methoxide ethoxide, magnesium ethoxide n-propoxide, magnesium di(2-methyl-1 -pentoxide), magnesium di(2-methyl-1 -hexoxide), magnesium di(2-methyl-1 -heptoxide), magnesium di(2-ethyl-1 -pentoxide), magnesium di(2-ethyl-1 -hexoxide), magnesium di(2-ethyl-1 -heptoxide), magnesium di(2-propyl-1 -heptoxide), magnesium di(2-methoxy-1 -ethoxide), magnesium di(3-methoxy-1 -propoxide), magnesium di(4-methoxy-1-butoxide), magnesium di(6-methoxy-1 -hexoxide), magnesium di(2-ethoxy-1 -ethoxide), magnesium di(3-ethoxy-1 -propoxide), magnesium di(4-ethoxy-1 -butoxide), magnesium di(6-ethoxy-1 -hexoxide), magnesium dipentoxide, magnesium dihexoxide.
Preference is given to using the simple magnesium alkoxides such as magnesium diethoxide, magnesium di-n-propoxide and magnesium di-i-butoxide.
The magnesium alkoxide is used as a suspension or as a gel dispersion.
The magnesium alkoxide is firstly reacted with a tetravalent transition metal compound of the formula Il
M1Xm(OR3)4-m (II),
where M1 is titanium, zirconium or hafnium, preferably titanium or zirconium, R3 is an alkyl radical having from 1 to 9, preferably from 1 to 4 carbon atoms and X is a halogen atom, preferably chlorine, and m is from zero to 4, preferably from 2 to 4.
Examples which may be mentioned are: TiCI4, TiCI3(OC2H5), TiCI2(OC2Hg)2, TiCI(OC2Hs)3, Ti(OC2Hg)4, TiCI3(OC3H7),
TiCI2(OC3H7)2, TiCI(OC3H7)S, Ti(OC3H7)4, TiCI3(OC4H9), TiCI2(OC4Hg)2, TiCI(OC4Hg)3, Ti(OC4Hg)4, TiCI3(OC6H13), TiCI2(OC6H13)2, TiCI(OC6H13)3, Ti(OC6H13)4, Ti(OC9H19)4, TiBr4, TiBr3(OR3), TiBr2(OR3)2, TiBr(OR3)3, TiI4, TiI3(OR3), Til2(OR3)2, Til(OR3)3, ZrCI4, ZrBr4, ZrI4, Zr(OC2H5)4, Zr(OC3H7)4, Zr(OC4Hg)4, ZrCI2(OC3Hy)2; preference is given to using TiCI4, ZrCI4, Ti(OC2H5)4, Ti(OC3Hy)4, Zr(OC3Hy)4, Ti(OC4Hg)4 and Zr(OC4Hg)4. Particular preference is given to TiCI4.
The reaction of the magnesium alkoxide with the tetravalent transition metal compounds is carried out at a temperature at from 20 to 1400C, preferably from 60 to 900C, over a period of from 1 to 20 hours.
Suitable inert suspension media for the abovementioned reactions include aliphatic and cycloaliphatic hydrocarbons such as butane, pentane, hexane, heptane, cyclohexane, isooctane and also aromatic hydrocarbons such as benzene and xylene. Petroleum spirit and hydrogenated diesel oil fractions which have carefully been freed of oxygen, sulfur compounds and moisture can also be used.
The magnesium alkoxide and the tetravalent transition metal compound (M1) are reacted in a molar ratio of Mg:M1 of 1 :0.05 - 10, preferably 1 :0.1 - 3.5.
Subsequent to the reaction, the suspension of the solid is stirred at from 90 to 2000C, preferably from 100 to 14O0C, for from 20 to 180 minutes, preferably from 30 to 90 minutes, and then washed until the supernatant mother liquor has Cl and Ti (Zr1Hf) concentrations of less than 10 mmol/l. As catalyst component B, use is made of a trialkylaluminum having from 1 to 6 carbon atoms in the alkyl radical, e.g. triethylaluminum, triisobutylaluminum, triisohexylaluminum, or the reaction product of a trialkylaluminum or dialkylaluminum hydride with isoprene known as isoprenylaluminum. Preference is given to triethylaluminum and triisobutylaluminum.
The mixing of the component A and the component B can be carried out in a stirred vessel at a temperature of from -3O0C to 15O0C prior to the polymerization. It is also possible to combine the two components directly in the polymerization vessel at a polymerization temperature of from 200C to 2000C. However, the addition of the component B can also be carried out in two steps by preactivating the component A with part of the component B at a temperature of from -300C to 1500C prior to the polymerization reaction and adding the remainder of the component B in the polymerization reactor at a temperature of from 200C to 2000C.
It is also possible firstly to prepolymerize the catalyst system with α-olefins, preferably linear C2-Cio-1-alkenes and in particular ethylene or propylene, and then to use the resulting prepolymerized catalyst solid in the actual polymerization. The mass ratio of catalyst solid used in the prepolymerization to monomer polymerized onto it is usually in the range from 1 :0.1 to 1 :20.
It is also possible to isolate the catalyst in the unprepolymerized form or in the prepolymerized form and store it as a solid and resuspend it on later use.
The polymerization is carried out in one or more stages, preferably as a suspension polymerization, in an inert suspension medium. Suitable suspension media are the same organic solvents as have been described for the preparation of the catalyst component A. However, polymerization in the gas phase is also possible.
The polymerization temperature is from 20 to 120°C, preferably from 70 to 9O0C, and the pressure is in the range from 0.2 to 6.0 MPa, preferably from 0.4 to 2.0 MPa.
If the reaction is carried out in two stages, the ratio of the polyolefins of differing molar mass formed in the stages 1 and 2 is in the range from 30:70 to 70:30.
The catalyst system used according to the invention is employed to polymerize ethylene or ethylene with up to 10% by weight, based on the total amount of monomers, of a 1 -olefin of the formula R7-CH=CH2, where R7 is a straight-chain or branched alkyl radical having from 1 to 12, preferably fom 1 to 10, carbon atoms. Examples are propylen, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1- pentene. Preference is given to using propylene, 1-butene and 1-hexene. The comonomer is preferably introduced in the second stage in which a polymer having the higher molar mass is formed.
The total polymer after the second stage is separated off from the dispersion medium and dried in a known manner.
Characteristics of the catalyst component A are a reduced time requirement compared to the prior art and a significantly reduced energy consumption. In addition, a further increase in the polymerization activity of the catalyst to a high level is astonishingly found. This was particularly surprising because the known Ziegler catalysts are themselves known for a high polymerization activity.
The particle size distribution of the polymer is very uniform.
The molar mass of the polyolefins is regulated efficiently by means of hydrogen in the presence of the catalyst used according to the invention.
The invention is illustrated for a person skilled in the art by means of the examples described below.
The results for the elemental composition of the catalysts described reported in the examples were obtained by the following analytical methods:
Ti: photometrically via the peroxide complex
Mg, Cl: titrimetrically by customary methods
The product properties of the polymer powders reported in the tables were determined by the following methods:
MFR5/igo: mass flow rate (melt index) in accordance with ISO1133, nominal load = 5 kg and test temperature = 19O0C FRR21.6/5: flow rate ratio; quotient of MFR21.6/190 and MFR5/i90 VN (viscosity number): in accordance with DIN EN ISO 1628-3 Bulk density: in acccordance with DIN EN ISO 60 dδo (mean particle diameter): in accordance with DIN 53477 and DIN66144 Mw/Mn (polydispersity): Measure of the width of the molar mass distribution
(Mw= weight average, Mn = number average), determined by the GPC method in accordance with DIN55672. The measurements were carried out at 135°C using trichlorobenzene as solvent.
Example 1 (according to the invention)
a) Preparation of the catalyst component A: In a 1 dm3 four-neck flask provided with reflux condenser, stirrer and inert gas blanketing (Ar), 57 g (O.δmol) of Mg(OC2H5)2 were suspended in 0.5 dm3 of diesel oil having a boiling range from 140 to 1700C (hydrogenated petroleum fraction). 237 g (1.25 mol) of TiCI4 were then added dropwise at 85°C over a period of 5 hours. After an after-reaction time of 0.5 hour, the suspension was heated at 1350C for 1 hour. It was then cooled to 60 - 700C and, after the solid had settled, the supernatant liquid phase (mother liquor) was taken off. The solid was subsequently resuspended in fresh diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 1700C) and after a stirring time of 15 minutes and subsequent complete settling of the solid, the supernatant liquid phase was taken off again. This washing procedure was repeated until the titanium concentration of the mother liquor was then less than 10 mmol/dm3.
The suspension was cooled to room temperature. The molar ratio of the solid (= catalyst component A) was:
Mg:Ti:CI « 1 :0.26:2.32.
b) Ethylene polymerization in suspension:
800 cm3 of diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 17O0C) were placed in a 1.5 dm3 reactor. The reactor was then heated to 85°C and, under a blanket of nitrogen, 2 mmol of triethylaluminum as cocatalyst (=catalyst component B) and subsequently the catalyst component A prepared as described in Example 1a in an amount corresponding to 0.05 mmol of titanium, as a suspension diluted with diesel oil, were introduced into the reactor. The reactor was then pressurized with 3.15 bar of hydrogen and 3.85 bar of ethylene. The total pressure of 7 bar was kept constant during the polymerization time of 2 hours by replacing the ethylene which had been consumed. The polymerization was stopped by shutting off the ethylene feed and venting of the gases. The polymer powder was separated off from the dispersion medium by filtration and drying.
The results of the polymerization are shown below in Table 1.
Example 2 (according to the invention)
The preparation of the catalyst component A was carried out as described in Example 1 except that the mixture was heated at 1200C for 1 hour after the addition of TiCI4.
After washing was complete, the suspension was cooled to room temperature. The molar ratio of the solid (= catalyst component A) was: Mg:Ti:CI « 1 :0.18:2.29.
The ethylene polymerization in suspension was carried out as described in Example 1b). The results of the polymerization are listed below in Table 1.
Example 3 (according to the invention)
a) Preparation of the catalyst component A:
In a 1 dm3 four-neck flask provided with reflux condenser, stirrer and inert gas blanketing (Ar), 57 g (O.δmol) of Mg(OC2H5)2 were suspended in 0.5 dm3 of diesel oil having a boiling range from 140 to 1700C (hydrogenated petroleum fraction). 190 g (1 mol) Of TiCI4 were then added dropwise at 850C over a period of 5 hours. After an after-reaction time of 0.5 hour, the suspension was heated at 1200C for 1 hour. It was then cooled to 60 - 70°C and, after the solid had settled, the supernatant liquid phase (mother liquor) was taken off. The solid was subsequently resuspended in fresh diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 17O0C) and after a stirring time of 15 minutes and subsequent complete settling of the solid, the supernatant liquid phase was taken off again. This washing procedure was repeated until the titanium concentration of the mother liquor was then 10 mmol/dm3. After the washing step was concluded, the suspension was cooled to room temperature. The molar ratio of the solid was:
Mg:Ti:CI * 1 :0.14:2.28.
b) Ethylene polymerization in suspension:
The polymerization is carried out as described in Example 1 b), except that the catalyst component A prepared as described in Example 3a was introduced into the reactor in an amount corresponding to 0.03 mmol of titanium as a suspension diluted with diesel oil. The results of the polymerization are shown below in Table 1.
Comparative Example 1
The preparation of the catalyst component A was carried out by the method described in Example 2, except that the mixture was heated at 1200C for 4 hours.
The suspension was then cooled to room temperature. The molar ratio of the solid was: Mg:Ti:CI « 1 :0.44:2.54.
The polymerization is carried out as described in Example 1 , except that the catalyst component A prepared as described in Comparative Example 1 was introduced into the reactor in an amount corresponding to 0.04 mmol of titanium as a suspension diluted with diesel oil. The results of the polymerization are shown below in Table 1.
Comparative Example 2
In a 1 dm3 four-neck flask provided with reflux condenser, stirrer and inert gas blanketing (Ar), 57 g (O.δmol) of Mg(OC2H5^ were suspended in 0.5 dm3 of diesel oil having a boiling range from 140 to 17O0C (hydrogenated petroleum fraction). 161 g (0.85 mol) Of TiCI4 were then added dropwise at 85°C over a period of 4 hours. After an after-reaction time of 0.5 hour, the reaction mixture was cooled to 60 - 700C and, after the solid had settled, the supernatant liquid phase (mother liquor) was taken off. The solid was subsequently resuspended in fresh diesel oil (hydrogenated petroleum Traction having a boiling range from 140 to 1700C) and after a stirring time of 15 minutes and subsequent complete settling of the solid, the supernatant liquid phase was taken off again. This washing procedure was repeated until the titanium concentration of the mother liquor was 40 - 50 mmol/dm3. The suspension was subsequently heated at 12O0C for 18 hours.
The suspension was then cooled to room temperature. The molar ratio of the solid was: Mg:Ti:CI « 1:0.32:2.22.
The polymerization is carried out as described in Example 1 , except that the catalyst component A prepared as described in Comparative Example 2 was introduced into the reactor in an amount corresponding to 0.1 mmol of titanium as a suspension diluted with diesel oil. The results of the polymerization are shown below in Table 1.
Table 1: Polymerization experiments in 1.5 dm3 reactor, 2 mmol of triethylaluminum, 0.8 dm3 of diesel oil, polymerization temperature: 85°C, 3.15 bar of H2, 3.85 bar of C2 (total pressure: 7 bar), polymerization time: 2 h
Figure imgf000011_0001
It can clearly be seen from the values in Table 1 that polymers having a broad molar mass distribution can be prepared advantageously at a higher polymerization activity by the process of the invention.
Example 4 (according to the invention)
a) Preparation of the catalyst component A:
In a 130 I reactor equipped with an impeller stirrer and baffles, 4.5 kg (=39mol) of Mg(OC2Hδ)2 were suspended in 59 dm3 of diesel oil having a boiling range from 140 to 1700C (hydrogenated petroleum fraction). 18.7 kg (= 98 mol) of TiCI4 were then added at 850C over a period of 5 hours. After an after-reaction time of 0.5 hour, the mixture was heated at T=120°C for 1 hour. 35 dm3 of diesel oil having a boiling range from 140 to 1700C (hydrogenated petroleum fraction) were then added and the mixture was cooled to T=70°C. After the solid had settled, the supernatant liquid phase (mother liquor) was then decanted off to a residual volume of 50 dm3. 55 dm3 of fresh diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 170°C) were subsequently introduced. After a stirring time of 20 minutes, the supernatant liquid was again decanted off to a residual volume of 50 dm3. This washing procedure was repeated until the titanium concentration of the mother liquor was less than 10 mmol/dm3.
The suspension was then cooled to room temperature. The molar ratio of the solid (= catalyst component A) was:
Mg:Ti:CI » 1 :0.14:2.30.
b) Ethylene polymerization in suspension:
The polymerization experiments were carried out batchwise in a 200 dm3 reactor. This reactor was equipped with an impeller stirrer and baffles. The temperature in the reactor was measured and automatically kept constant. The polymerization temperature was 85 ± 1 0C.
The polymerization reaction was carried out in the following way: 100 dm0 of diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 1700C) were placed in the N2-blanketed reactor and heated to 85°C. Under a blanket of inert gas (N2), 60 mmol of triethylaluminum were added as cocatalyst (= catalyst component B) and the catalyst component A prepared as described in Example 4a was subsequently introduced into the reactor in an amount corresponding to 3.0 mmol of titanium as a suspension diluted with diesel oil. The molar aluminum/titanium ratio was thus 20:1.
The reactor was pressurized a number of times with H2 (hydrogen) to 8 bar and depressurized again to remove the nitrogen completely from the reactor (the procedure was monitored by measurement of the H2 concentration in the gas space of the reactor, which finally indicated 95% by volume). The polymerization was started by opening the ethylene inlet. Ethylene was introduced in an amount of 8.0 kg/h over the entire polymerization time, with the pressure in the reactor rising slowly. The concentration of hydrogen in the gas space of the reactor was measured continually and the proportion by volume was kept constant by introducing appropriate amounts of hydrogen (% by volume of H2 = 50 - 55).
The polymerization was stopped after 225 minutes (total of 30 kg of ethylene gas fed in) and the total pressure was read off. The contents of the reactor were drained onto a filter. The polymer which was moist with diesel oil was dried in a stream of nitrogen over a period of several hours.
The results of the polymerizations are shown in Table 2.
Example 5 (according to the invention)
In a 1 dm3 four-neck flask provided with reflux condenser, stirrer and inert gas blanketing (Ar), 500 cm3 of the suspension of the catalyst component A prepared as described in Example 4a, which had a concentration of 0.09 mol/l based on titanium, were admixed with 6.2 ml of triethylaluminum. The mixture was stirred at 1200C for 2 hours. 100% of the titanium(IV) was reduced to titanium(lll) by means of this preactivation process. The polymerization of ethylene over the preactivated catalyst component A was carried out by a method analogous to that described in Example 4b).
The results of the polymerizations are listed in Table 2.
Example 6 (according to the invention)
a) Preparation of the catalyst component A as dry catalyst: The suspension prepared by the method described in Example 4a was diluted with 25 dm3 of diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 1700C). It was then heated to T=65°C and 150 mmol of triethylaluminum were added. While stirring, the reactor was flushed three times with 2 bar of hydrogen and then pressurized with 3 bar of hydrogen. A total of 5.3 kg of ethylene were subsequently metered in at a rate of 0.5 kg/h.
After cooling to room temperature, a sample of 0.5 dm3 was taken from this prepolymerized catalyst suspension. Under a blanket of inert gas (Ar), the solid was allowed to settle and the supernatant diesel oil was then decanted off and the solid was washed twice with hexane. The solid was then dried at 800C under reduced pressure on a rotary evaporator. This concluded the preparation of the prepolymerized catalyst component A as dry catalyst.
The polymerization of ethylene over the prepolymerized catalyst component A was carried out by a method analogous to that described in Example 4b). For this purpose, the dry catalyst described in Example 6a was resuspended in diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 1700C).
The results of the polymerizations are listed in Table 2.
Comparative Example 3
In a 2 dm3 four-neck flask provided with reflux condenser, stirrer and inert gas blanketing (Ar), 114 g (1 mol) Of Mg(OC2Hs)2 were suspended in 1 dm3 of diesel oil having a boiling range from 140 to 17O0C (hydrogenated petroleum fraction). 237 g (1.25 mol) of TiCI4 were then added dropwise at 85°C over a period of 5 hours. After an after-reaction time of 0.5 hour, the mixture was cooled to 60 - 7O0C and, after the solid had settled, 0.5 dm3 of the supernatant liquid phase (mother liquor) were taken off and 1.1 dm3 of fresh diesel oil (hydrogenated petroleum fraction having a boiling range from 140 to 1700C) were subsequently added. After 1.1 dm3 of dispersion medium had been introduced a total of four times and in each case 1.1 dm3 of supernatant solution had been taken off again, 0.9 dm3 of diesel oil was introduced and the suspension was stirred at 12O0C for 18 hours.
The suspension was cooled to room temperature. The molar ratio of the solid was: Mg:Ti:CI « 1 :0.15:2.13.
The polymerization was carried out as described in Example 4, except that 120 mmol of triethylaluminum as cocatalyst (= catalyst component B) and subsequently the catalyst component A prepared as described in Comparative Example 3 in an amount corresponding to 6.0 mmol of titanium, as a suspension diluted with diesel oil, were introduced into the reactor. The molar aluminum/titanium ratio was thus 20:1.
The results of the polymerization are shown below in Table 2.
Table 2: Polymerization experiments in 200 dm3 reactor, 100 dm3 of diesel oil, polymerization temperature: 85°C, 50 - 55% by volume of H2 , Al/Ti = 20:1 , 8 kg/h of ethylene feed gas, yield: 30 kg, polymerization time: 3.75 h
Figure imgf000016_0001
It can clearly be seen from the values in Table 2 that polymers having a broad molar mass distribution can be prepared advantageously at significantly increased polymerization activities by the process of the invention.

Claims

Claims
1. A process for preparing an olefin polymer by (co)polymerization of ethylene or of ethylene with up to 10% by weight, based on the total amount of monomers, of a 1 -olefin of the formula R-CH=CHb, where R is a straight-chain or branched alkyl radical having from 1 to 12 carbon atoms, in suspension, in solution or in the gas phase, at a temperature of from 20 to 1200C, and a pressure of from 0.2 to 6.0 MPa in the presence of a catalyst comprising the reaction product of a magnesium alkoxide with a tetravalent transition metal compound, wherein a magnesium alkoxide of the formula I
Mg(OR1XOR2) (I),
where R1 and R2 are identical and are each an unbranched or branched alkyl radical having from 1 to 20 carbon atoms or a radical (CH2)nOR3, where R3 is an alkyl radical having from 1 to 4 carbon atoms and n is an integer from 2 to 6, suspended or dispersed as gel in an inert solvent, is reacted with a tetravalent transition metal compound of the formula Il
M1Xm(OR4)4-m (II),
where M1 is titanium, zirconium or hafnium, R4 is an alkyl radical having from 1 to 9 carbon aotms and X is a halogen atom and m is an integer from zero to 4, at a temperature in the range from 20 to 1400C and the reaction product is then after-treated thermally at a temperature in the range from 90 to 2000C for a period of from 10 to 180 minutes.
2. The process according to claim 1 , wherein R1 and R2 in the formula (I) are identical or different and are each an unbranched or branched alkyl radical having from 2 to 10 carbon atoms or a radical -(CH2)nOR6, where R6 is a Cr
C2-alkyl radical and n is an integer from 2 to 6.
3. The process according to claim 1 or 2, wherein the reaction of the magnesium alkoxide with the tetravalent transition metal compound is carried out at a temperature of from 20 to 140°C over a period of from 1 to 20 hours.
4. The process according to one or more of claims 1 to 3, wherein aliphatic and cycloaliphatic hydrocarbons such as butane, pentane, hexane, heptane, cyclohexane, isooctane or aromatic hydrocarbons such as benzene and xylene or else petroleum spirit and hydrogenated diesel oil fractions are used as inert suspension media.
5. The process according to one or more of claims 1 to 4, wherein the magnesium alkoxide and the tetravalent transition metal compound (M1) are used in a molar ratio of Mg:M1 of 1 :0.05 - 0, preferably 1 :0.1-3.5.
6. The process according to one or more of claims 1 to 5, wherein the suspension of the solid is stirred at a temperature of from 90 to 2000C, preferably from 100 to 1400C, for from 20 to 180 minutes, preferably from 30 to 90 minutes, after the reaction and is then washed until the supernatant mother liquor has Cl and Ti (Zr1Hf) concentrations of less than 10 mmol/l.
7. The process according to one or more of claims 1 to 6, wherein a trialkylaluminum having from 1 to 6 carbon atoms in the alkyl radicals, e.g. triethylaluminum, triisobutylaluminum, triisohexylaluminum or the reaction product of a trialkylaluminum or dialkylaluminum hydride with isoprene, preferably triethylaluminum or triisobutylaluminum, is used as catalyst component B.
8. An ethylene polymer prepared by the process according to any of claims 1 to 7, which has a broad molar mass distribution expressed as Mw/Mn of greater than 6.9, preferably greater than or equal to 7.3.
9. The ethylene polymer according to claim 8, wherein the homopolymer or copolymer is prepared in a two-stage or multistage polymerization process.
10. The use of an ethylene polymer according to claim 8 or 9 for producing films by the film blowing process, for producing small and large hollow bodies by the blow molding process and for producing pipes by the extrusion process.
PCT/EP2006/001343 2005-02-16 2006-02-15 Process for preparing ethylene (co) polymers WO2006087170A1 (en)

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BRPI0606925A BRPI0606925B1 (en) 2005-02-16 2006-02-15 process for preparing an olefinic polymer
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