WO2024056727A1 - Composition de polyéthylène pour moulage par soufflage possédant un comportement de gonflement amélioré - Google Patents

Composition de polyéthylène pour moulage par soufflage possédant un comportement de gonflement amélioré Download PDF

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WO2024056727A1
WO2024056727A1 PCT/EP2023/075131 EP2023075131W WO2024056727A1 WO 2024056727 A1 WO2024056727 A1 WO 2024056727A1 EP 2023075131 W EP2023075131 W EP 2023075131W WO 2024056727 A1 WO2024056727 A1 WO 2024056727A1
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Prior art keywords
polyethylene composition
equal
mie
mif
weight
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PCT/EP2023/075131
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English (en)
Inventor
Ulf Schueller
Sebastian Wilhelm
Harald Schmitz
Bernd Lothar Marczinke
Andreas Maus
Elke Damm
Gerhardus Meier
Eric D. Day
Sameer D. Mehta
Harilaos Mavridis
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Basell Polyolefine Gmbh
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Priority claimed from US17/945,329 external-priority patent/US20240093009A1/en
Application filed by Basell Polyolefine Gmbh filed Critical Basell Polyolefine Gmbh
Publication of WO2024056727A1 publication Critical patent/WO2024056727A1/fr

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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
    • C08F8/00—Chemical modification by after-treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2308/00—Chemical blending or stepwise polymerisation process with the same catalyst
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2314/00—Polymer mixtures characterised by way of preparation
    • C08L2314/02—Ziegler natta catalyst

Definitions

  • the present disclosure relates to a polyethylene composition which is suitable for producing small articles by blow molding.
  • the EP2818509A1 discloses a polyethylene composition with improved balance of impact resistance at low temperatures and Environmental Stress Cracking Resistance (ESCR), particularly suited for producing protective coatings on metal pipes.
  • ESCR Environmental Stress Cracking Resistance
  • WO 2010025342 A2 discloses a process for injection blow molding an article, said process comprising injecting into a mold cavity a composition, comprising at least one ethylene-based polymer and less than, or equal to, 1000 ppm of a mold release agent, based on the total weight of the composition.
  • WO 2008/088464 Al a method of modifying a polyethylene is disclosed.
  • ethylene or a mixture of ethylene and a C3-C10 a-olefin is polymerized in an organic solvent with a Ziegler or single-site catalyst to form an initial polyethylene solution.
  • compositions suited for the said use are disclosed in W02018095700, W02018095701 and WO2018095702.
  • compositions due to a proper selection of their molecular structure and rheological behavior, achieve a particularly high Environmental Stress Cracking Resistance (ESCR) in a broad density range, in combination with an extremely smooth surface of the final article, with reduced gel content.
  • ESCR Environmental Stress Cracking Resistance
  • the parison swell has two components: weight swell and diameter swell. [0012] Weight swell can occur during the short time the molds are open and the parisons are dropping. The parisons may actually shrink in length and concurrently their walls thicken and become heavier.
  • narrow die gaps are extremely sensitive to impurities. Narrow die gaps also result in high shear which can lead to high diameter swell in the parison. The final bottle may be complete, but surrounded by heavy flash. Pleating can also be an issue.
  • the diameter swell is particularly critical for blow molded articles (in particular bottles) comprising a handle portion, thus generally called “handleware”.
  • the diameter swell can be expressed in terms of distance (length), e.g. in centimeters, the flash extends from the neck of the handleware item (including the protruding flash) to and possibly beyond the handle area.
  • ratio MIF/MIE from 60 to 125, preferably from 62 to 123, where MIF is the melt flow index at 190°C with a load of 21.60 kg, and MIE is the melt flow index at 190°C with a load of 2.16 kg, both determined according to ISO 1133-2:2011;
  • MIF from 15 to 40 g/10 min., preferably from 20 to 35 g/10 min., or from 25 to 40 g/10 min., in particular from 25 to 35 g/10 min.;
  • ER values from 3.0 to 5.5, or from 3.5 to 5.5, preferably from 3.0 to 5.2, or from 3.5 to 5.2, more preferably from 4.0 to 5.0, or from 3.5 to 4.8, most preferably from 4.2 to 5.2 or from 4.2 to 4.8;
  • o.o2 equal to or lower than 150,000 Pa.s, preferably equal to or lower than 100,000 Pa.s, more preferably equal to or lower than 80,000 Pa.s in particular from 150,000 to 25,000 Pa.s or from 100,000 to 25,000 Pa.s or from 80,000 to 25,000 Pa.s;
  • qo.02 is the complex viscosity of the melt, measured at a temperature of 190°C, in a parallel-plate (or so-called plate-plate) rheometer under dynamic oscillatory shear mode with an applied angular frequency of 0.02 rad/s;
  • G' storage-modulus
  • G" loss-modulus; both G' and G" being measured with dynamic oscillatory shear in a plate-plate rotational rheometer at a temperature of 190°C.
  • Said polyethylene composition can be easily processed in conventional blow molding apparatuses, as it fulfills the industrial requirements in terms of weight swell and diameter swell.
  • Figure 1 is an illustrative embodiment of a simplified process-flow diagram of two serially connected gas-phase reactors suitable for use in accordance with various embodiments of ethylene polymerization processes disclosed herein to produce various embodiments of the polyethylene composition disclosed herein.
  • Figure 2 depicts the test bottle used for the weight and diameter swell test. It is about 28 cm tall (excluding top and bottom flashes) and about 14 cm wide.
  • polyethylene composition is intended to embrace, as alternatives, both a single ethylene polymer and an ethylene polymer composition, in particular a composition of two or more ethylene polymer components, preferably with different molecular weights, such composition being also called “bimodal” or “multimodal” polymer in the relevant art.
  • the present polyethylene composition consists of or comprises one or more ethylene copolymers.
  • the ratio MIF/MIE provides a rheological measure of molecular weight distribution.
  • Another measure of the molecular weight distribution is provided by the ratio M w Mn, where M w is the weight average molecular weight and M n is the number average molecular weight, measured by GPC (Gel Permeation Chromatography), as explained in the examples.
  • Preferred M w /M n values for the present polyethylene composition range from 15 to 35, in particular from 18 to 35.
  • the Mw values are preferably from 150,000 g/mol to 450,000 g/mol, in particular from 150,000 g/mol to 350,000 g/mol.
  • the present polyethylene composition has preferably at least one of the following additional features:
  • FTIR - comonomer content equal to or less than 1.5% by weight
  • MIP melt flow index at 190°C with a load of 5 kg, determined according to ISO 1133-1 2012-03;
  • MIF/MIE MIF/MIE
  • ER - ratio (MIF/MIE)/ER, which is between MIF/MIE and ER, of equal to or less than 28, in particular from 28 to 15, or from 28 to 18;
  • LCBI long chain branching index LCBI equal to or greater than 0.55, more preferably equal to or greater than 0.62, the upper limit being preferably of 0.95 in all cases;
  • LCBI is the ratio of the measured mean-square radius of gyration Rg, measured by GPC-MALLS, to the mean-square radius of gyration for a linear PE having the same molecular weight at a mol. weight of 1,000,000 g/mol;
  • o.o2 equal to or greater than 35,000 Pa.s, more preferably equal to or greater than 40,000 Pa.s, in particular from 35,000 or 40,000 to 70,000 Pa.s;
  • HMWcopo index from 0.5 to 5, in particular from 0.5 to 3.5; where the HMWcopo index is determined according to the following formula:
  • HMWCOPO (T
  • the present polyethylene composition is obtained by using, in the polymerization stage, a Ziegler-Natta polymerization catalyst, details of which are hereinafter provided.
  • the present polyethylene composition can be advantageously used for producing blow molded articles, in particular handleware, like bottles with a handle portion, with valuable properties.
  • the gel content of the present polyethylene composition is preferably of less than 10 gels/m 2 , more preferably of less than 5 gels/m 2 , most preferably of less than 3 gels/m 2 , having diameter greater than 450 pm.
  • the total gel content is preferably of less than 350 gels/m 2 , more preferably of less than 300 gels/m 2 .
  • the swell ratio of the present polyethylene composition is preferably equal to or higher than 140%, in particular from 140% to 190%.
  • the blow-molding process is generally carried out by first plastifying the polyethylene composition in an extruder at temperatures in the range from 180 to 250°C and then extruding it through a die into a blow mold, where it is cooled.
  • the present polyethylene composition having the above defined features is obtained by contacting with a radical initiator a precursor polyethylene composition (I) having a ratio MIF/MIE I 1 ) lower than MIF/MIE 1) and preferably from 50 to 119, more preferably from 60 to 110; wherein the ratio I)/! 1 ), which is between the MIF/MIE 1) of the final polyethylene composition (after contacting with the radical initiator) and the MIF/MIE I 1 ) of the precursor polyethylene composition (I), is equal to or greater than 1.05, in particular from 1.05 to 1.8, or from 1.05 to 1.5.
  • the ratio 4)/4 r ), which is between the ER 4) of the final polyethylene composition (after contacting with the radical initiator) and the ER 4 1 ) of the precursor polyethylene composition (I), is from 1.1 to 2.5.
  • the precursor polyethylene composition (I) has the following additional features:
  • MIF from 20 to 50 g/10 min., preferably from 25 to 45 g/10 min.;
  • o.o2 equal to or lower than 150,000 Pa.s, preferably equal to or lower than 100,000 Pa.s, more preferably equal to or lower than 80,000 Pa.s, in particular from 150,000 to 15,000 Pa.s or from 100,000 to 15,000 Pa.s, or from 80,000 to 15,000 Pa.s.
  • precursor polyethylene composition (I) may preferably have at least one of the following further features:
  • comonomer or comonomers content equal to or less than 1.5% by weight, in particular from 0.1 to 1.5% by weight (FTIR), with respect to the total weight of the composition, the comonomer or comonomers being the same as reported above for the final polyethylene composition; in particular, the kind and amount of comonomer or comonomers are the same in the final polyethylene composition (after contact with the radical initiator) and in its precursor polyethylene composition (I);
  • - MIP of 0.3 g/10 min. or higher, more preferably of 0.5 g/10 min. or higher, in particular from 0.3 to 6 g/10 min., or from 0.5 to 6 g/10 min.;
  • MIF/MIE MIF/MIE/ER
  • - long chain branching index LCBI equal to or greater than 0.50, more preferably equal to or greater than 0.55, the upper limit being preferably of 0.90 in all cases;
  • o.o2 equal to or lower than 45,000 Pa.s, in particular from 45,000 to 20,000 Pa.s;
  • - HMWcopo index from 0.5 to 5, in particular from 0.5 to 3.5.
  • the precursor polyethylene composition (I) comprises: A) 30 - 70% by weight, preferably 40 - 60% by weight of an ethylene homopolymer or copolymer (the homopolymer being preferred) with density equal to or greater than 0.960 g/cm 3 and melt flow index MIE at 190°C with a load of 2.16 kg, according to ISO 1133, of 8 g/10 min. or higher, preferably of 40 g/10 min. or higher;
  • the precursor polyethylene composition (I) can be prepared by a gas phase polymerization process in the presence of a Ziegler-Natta catalyst.
  • a Ziegler-Natta catalyst comprises the product of the reaction of an organometallic compound of group 1, 2 or 13 of the Periodic Table of elements with a transition metal compound of groups 4 to 10 of the Periodic Table of Elements (new notation).
  • the transition metal compound can be selected among compounds of Ti, V, Zr, Cr and Hf and is preferably supported on MgCh.
  • Preferred organometallic compounds are the organo-Al compounds.
  • the precursor polyethylene composition (I) is obtainable by using a Ziegler-Natta polymerization catalyst, preferably a Ziegler-Natta catalyst comprising the product of reaction of:
  • A) a solid catalyst component comprising a Ti, Mg, chlorine and one or more internal electron donor compounds ED;
  • the solid catalyst component A) can comprise one internal electron donor ED selected from esters of aliphatic monocarboxylic acids (EAA) and another internal donor ED 1 selected from cyclic ethers (CE) in an amount such that the EAA/CE molar ratio ranges from 0.02 to less than 20.
  • EAA esters of aliphatic monocarboxylic acids
  • CE cyclic ethers
  • the EAA/CE molar ratio ranges from 0.2 to 16 and more preferably from 0.5 to 10.
  • the internal electron donor compound (EAA) is preferably selected from C1-C10, preferably C2-C5 alkyl esters of C2-C10, preferably C2-C6, aliphatic monocarboxylic acids. Among them, particularly preferred is ethyl acetate.
  • the (CE) internal donor is preferably selected from cyclic ethers having 3-5 carbon atoms and, among them, tetrahydrofuran, tetrahydropirane and dioxane are the most preferred with tetrahydrofuran being especially preferred.
  • the (EAA+CE)/Ti molar ratio is preferably higher than 1.5, and more preferably ranges from 2.0 to 10, especially from 2.5 to 8.
  • the content of (EAA) typically ranges from 1 to 30%wt with respect to the total weight of the solid catalyst component, more preferably from 2 to 20%wt.
  • the content of (CE) typically ranges from 1 to 20%wt with respect to the total weight of the solid catalyst component, more preferably from 2 to 10%wt.
  • the Mg/Ti molar ratio preferably ranges from 5 to 50, more preferably from 10 to 40.
  • the catalyst component comprises, in addition to the electron donor compounds, Ti, Mg and chlorine.
  • the Ti atoms preferably derive from a Ti compound containing at least a Ti-halogen bond and the Mg atoms preferably derive from a magnesium dichloride.
  • Preferred titanium compounds are the tetrahalides or the compounds of formula TiX n (OR 1 )4-n, where 0 ⁇ n ⁇ 3, X is halogen, preferably chlorine, and R 1 is C1-C10 hydrocarbon group. Titanium tetrachloride is the preferred titanium compound.
  • the catalyst component of the present disclosure can be prepared according to different methods.
  • One preferred method comprises the following steps: (a) contacting a MgX 2 (R 2 OH) m adduct in which R 2 groups are C1-C20 hydrocarbon groups and X is halogen, with a liquid medium comprising a Ti compound having at least a Ti-Cl bond, in an amount such that the Ti/Mg molar ratio is greater than 3, thereby forming a solid intermediate;
  • Preferred starting MgX2(R 2 OH) m adducts are those in which R 2 groups are C1-C10 alkyl groups, X is chlorine and m is from 0.5 to 4, more preferably from 0.5 to 2.
  • Adducts of this type can generally be obtained by mixing alcohol and magnesium chloride in the presence of an inert hydrocarbon immiscible with the adduct, operating under stirring conditions at the melting temperature of the adduct (100-130°C). Then, the emulsion is quickly quenched, thereby causing the solidification of the adduct in form of spherical particles.
  • MgC12(EtOH) m adducts in which m is from 0.15 to 1.5 and particle size ranging from 10 to 100 pm obtained by subjecting the adducts with a higher alcohol content to a thermal dealcoholation process carried out in nitrogen flow at temperatures comprised between 50 and 150°C until the alcohol content is reduced to the above value.
  • a process of this type is described in EP 395083.
  • the dealcoholation can also be carried out chemically by contacting the adduct with compounds capable of reacting with the alcohol groups.
  • these dealcoholated adducts are also characterized by a porosity (measured by mercury method) due to pores with radius up to 1 m ranging from 0.15 to 2.5 cm 3 /g, preferably from 0.25 to 1.5 cm 3 /g.
  • the reaction with the Ti compound can be carried out by suspending the adduct in TiCh (which is generally cold); subsequently the mixture is heated up to temperatures ranging from 80-130°C and kept at this temperature for 0.5-2 hours.
  • the treatment with the titanium compound can be carried out one or more times. Preferably, it is carried out two times.
  • the intermediate solid is recovered by separation of the suspension via the conventional methods (such as settling and removing of the liquid, filtration and centrifugation) and can be subject to washings with solvents. Although the washings are typically carried out with inert hydrocarbon liquids, it is also possible to use more polar solvents (having for example a higher dielectric constant) such as halogenated hydrocarbons.
  • the intermediate solid is, in step (b) brought into contact with the internal donor compounds under conditions such as to fix on the solid an amount of donors such that the EAA/CE molar ratio ranging from 0.02 to less than 20 is fulfilled.
  • the contact is typically carried out in a liquid medium such as a liquid hydrocarbon.
  • the temperature at which the contact takes place can vary depending on the nature of the reagents. Generally, it is comprised in the range from -10° to 150°C and preferably from 0° to 120°C. It is clear that temperatures causing the decomposition or degradation of any specific reagents should be avoided even if they fall within the generally suitable range.
  • the time of the treatment can vary in dependence of other conditions such as the nature of the reagents, temperature, concentration etc. As a general indication, this contact step can last from 10 minutes to 10 hours more frequently from 0.5 to 5 hours. If desired, in order to further increase the final donor content, this step can be repeated one or more times.
  • the solid is recovered by separation of the suspension via conventional methods (such as settling and removing of the liquid, filtration and centrifugation) and can be subject to washings with solvents.
  • washings are typically carried out with inert hydrocarbon liquids, it is also possible to use more polar solvents (having, for example, a higher dielectric constant) such as halogenated or oxygenated hydrocarbons.
  • step (b) a further step (c) is carried out by subjecting the solid catalyst component coming from (b) to a thermal treatment carried out at a temperature from 70 to 150°C.
  • step (c) of the method the solid product recovered from step (b) is subject to a thermal treatment carried out at temperatures ranging from 70 to 150°C, preferably from 80°C to 130°C, and more preferably from 85 to 100°C.
  • the thermal treatment can be carried out in several ways. According to one of them the solid coming from step (b) is suspended in an inert diluent like a hydrocarbon and then subject to the heating while maintaining the system under stirring.
  • the solid can be heated in a dry state by inserting it in a device having jacketed heated walls. While stirring can be provided by means of mechanical stirrers placed within said device, it is preferred to cause stirring to take place by using rotating devices.
  • the solid coming from (b) can be heated by subjecting it to a flow of hot inert gas such as nitrogen, preferably by maintaining the solid under fluidization conditions.
  • hot inert gas such as nitrogen
  • the heating time is not fixed but may vary depending on other conditions such as the maximum temperature reached. It generally ranges from 0.1 to 10 hours, more specifically from 0.5 to 6 hours. Usually, higher temperatures allow the heating time to be shorter while lower temperatures may require longer reaction times.
  • each of the steps (b)-(c) can be carried out immediately after the previous step, without the need of isolating the solid product coming from that previous step.
  • the solid product coming from one step can be isolated and washed before being subject to the subsequent step.
  • a preferred modification of the process comprises subjecting the solid coming from step (a) to a prepolymerization step (a2) before carrying out step (b).
  • the prepolymerization step can be carried out at temperatures from 0 to 80°C, preferably from 5 to 70°C, in the liquid or gas phase.
  • the pre-polymerization of the intermediate with ethylene or propylene in order to produce an amount of polymer ranging from 0.5 to 20 g per gram of intermediate is particularly preferred.
  • the pre-polymerization is carried out with the use of a suitable cocatalyst such as organoaluminum compounds.
  • the prepolymerization is carried out in the presence of one or more external donors preferably selected from the group consisting of silicon compounds of the general formula R a 4 Rb 5 Si(OR 6 ) c , where a and b are integer from 0 to 2, c is an integer from 1 to 3 and the sum (a+b+c) is 4; R 4 , R 5 , and R 6 , are alkyl, cycloalkyl or aryl radicals with 1-18 carbon atoms optionally containing heteroatoms.
  • one or more external donors preferably selected from the group consisting of silicon compounds of the general formula R a 4 Rb 5 Si(OR 6 ) c , where a and b are integer from 0 to 2, c is an integer from 1 to 3 and the sum (a+b+c) is 4; R 4 , R 5 , and R 6 , are alkyl, cycloalkyl or aryl radicals with 1-18 carbon atoms optionally containing heteroatoms.
  • R 4 and R 5 is selected from branched alkyl, cycloalkyl or aryl groups with 3-10 carbon atoms optionally containing heteroatoms
  • R 6 is a Ci-Cio alkyl group, in particular methyl.
  • Examples of such preferred silicon compounds are methylcyclohexyldimethoxysilane (C donor), diphenyldimethoxysilane, methyl-t-butyldimethoxysilane, dicyclopentyldimethoxysilane (D donor) and diisopropyldimethoxysilane.
  • All of the above mentioned processes are suitable for the preparation of particles of solid catalyst components having substantially spherical morphology and average diameter comprised between 5 and 150 pm, preferably from 10 to 100 pm.
  • particles having substantially spherical morphology those are meant wherein the ratio between the greater axis and the smaller axis is equal to, or lower than 1.5, and preferably lower than 1.3.
  • the solid catalyst components obtained according to the above method show a surface area (by B.E.T. method) generally between 10 and 200 m 2 /g and preferably between 20 and 80 m 2 /g, and a total porosity (by B.E.T. method) higher than 0.15 cm 3 /g preferably between 0.2 and 0.6 cm 3 /g.
  • the porosity (Hg method) due to pores with radius up to 10.000 A generally ranges from 0.25 to 1 cm 3 /g, preferably from 0.35 to 0.8 cm 3 /g.
  • the catalyst components of the disclosure form polymerization catalysts by reaction with Al-alkyl compounds.
  • Al-trialkyl compounds for example Al-trimethyl, Al-triethyl, Al-tri-n-butyl, Al-triisobutyl are preferred.
  • the Al/Ti ratio is higher than 1 and is generally comprised between 5 and 800.
  • alkylaluminum halides and in particular alkylaluminum chlorides such as diethylaluminum chloride (DEAC), diisobutylaluminum chloride, Al-sesquichloride and dimethylaluminum chloride (DMAC) can be used. It is also possible to use, and in certain cases preferred, mixtures of trialkylaluminum compounds with alkylaluminum halides. Among them mixtures TEAL/DEAC and TIBA/DEAC are particularly preferred.
  • an external electron donor can be used during polymerization.
  • the external electron donor compound can be equal to, or different from, the internal donors used in the solid catalyst component.
  • it is selected from the group consisting of ethers, esters, amines, ketones, nitriles, silanes and mixtures of the above.
  • it can advantageously be selected from the C2-C20 aliphatic ethers and especially from cyclic ethers preferably having 3-5 carbon atoms such as tetrahydrofuran and dioxane.
  • a halogenated compound (D) is preferably a mono- or dihalogenated hydrocarbon. In one preferred embodiment, it is chosen among monohalogenated hydrocarbons in which the halogen is linked to a secondary carbon atom.
  • the halogen is preferably chosen from among chloride and bromide.
  • Non-limiting exemplary compounds for (D) are propyl chloride, i-propylchloride, butyl chloride, s-butylchloride, t-butylchloride 2-chlorobutane, cyclopentylchloride, cyclohexylchloride, 1,2-di chloroethane, 1,6-di chlorohexane, propylbromide, i- propylbromide, butylbromide, s-butylbromide, t-butylbromide, i-butylbromide i- pentylbromide, and t-pentylbromide.
  • i-propylchloride 2-chlorobutane
  • cyclopentylchloride cyclohexylchloride
  • 1,4-di chlorobutane 2- bromopropane
  • the compounds can be chosen from among halogenated alcohols, esters or ethers such as 2, 2, 2, -trichloroethanol, ethyl trichloroacetate, butyl perchlorocrotonate, 2-chloro propionate and 2-chloro-tetrahydrofurane.
  • halogenated alcohols esters or ethers
  • esters or ethers such as 2, 2, 2, -trichloroethanol, ethyl trichloroacetate, butyl perchlorocrotonate, 2-chloro propionate and 2-chloro-tetrahydrofurane.
  • the activity enhancer can be used in amounts such as to have the (B)/(D) molar ratio of higher than 3 and preferably in the range 5-50 and more preferably in the range 10-40.
  • the above mentioned components (A)-(D) can be fed separately into the reactor under the polymerization conditions to exploit their activity. It constitutes however a particular advantageous embodiment the pre-contact of the above components, optionally in the presence of small amounts of olefins, over a period of time ranging from 1 minute to 10 hours, preferably in the range from 2 to 7 hours.
  • the pre-contact can be carried out in a liquid diluent at a temperature ranging from 0 to 90°C preferably in the range of 20 to 70°C.
  • One or more alkyl aluminum compound or mixtures thereof can be used in the precontact. If more than one alkylaluminum compound is used in the pre-contact, they can be used altogether or added sequentially to the pre-contact tank. Even if the pre-contact is carried out, it is not necessary to add at this stage the whole amount of aluminum alkyl compounds. A portion thereof can be added in the pre-contact while the remaining aliquot can be fed to the polymerization reactor. Moreover, when more than one aluminum alkyl compound is used, it is also possible using one or more in the precontact process and the other(s) fed to the reactor.
  • a precontact is carried out by first contacting the catalyst component with an aluminum trialkyl such as tri-n-hexyl aluminum (THA), then another aluminum alkyl compound, preferably, diethylaluminum chloride is added to the mixture, and finally as a third component another trialkylaluminum, preferably, triethylaluminum is added to the pre-contact mixture.
  • an aluminum trialkyl such as tri-n-hexyl aluminum (THA)
  • another aluminum alkyl compound preferably, diethylaluminum chloride
  • another trialkylaluminum preferably, triethylaluminum is added to the pre-contact mixture.
  • the last aluminum trialkyl is added to the polymerization reactor.
  • the total amount of aluminum alkyl compounds used can vary within broad ranges, but it preferably ranges from 2 to 10 mols per mole of internal donor in the solid catalyst component.
  • the precursor polyethylene composition (I) can be prepared in a process comprising the following steps, in any mutual order: a) polymerizing ethylene, optionally together with one or more comonomers, in a gasphase reactor in the presence of hydrogen; b) copolymerizing ethylene with one or more comonomers in another gas-phase reactor in the presence of an amount of hydrogen less than step a); where in at least one of said gas-phase reactors the growing polymer particles flow upward through a first polymerization zone (riser) under fast fluidization or transport conditions, leave said riser and enter a second polymerization zone (downcomer) through which they flow downward under the action of gravity, leave said downcomer and are reintroduced into the riser, thus establishing a circulation of polymer between said two polymerization zones.
  • fast fluidization conditions are established by feeding a gas mixture comprising one or more olefins (ethylene and comonomers) at a velocity higher than the transport velocity of the polymer particles.
  • the velocity of said gas mixture is preferably comprised between 0.5 and 15 m/s, more preferably between 0.8 and 5 m/s.
  • transport velocity and fast fluidization conditions are well known in the art; for a definition thereof, see, for example, "D. Geldart, Gas Fluidisation Technology, page 155 et seq. , J. Wiley & Sons Ltd. , 1986".
  • the polymer particles flow under the action of gravity in a densified form, so that high values of density of the solid are reached (mass of polymer per volume of reactor), which approach the bulk density of the polymer.
  • the polymer flows vertically down through the downcomer in a plug flow (packed flow mode), so that only small quantities of gas are entrained between the polymer particles.
  • step a) an ethylene polymer with a molecular weight lower than the ethylene copolymer obtained from step b).
  • a copolymerization of ethylene to produce a relatively low molecular weight ethylene copolymer is performed upstream the copolymerization of ethylene to produce a relatively high molecular weight ethylene copolymer (step b).
  • a gaseous mixture comprising ethylene, hydrogen, comonomer and an inert gas is fed to a first gas-phase reactor, preferably a gas-phase fluidized bed reactor.
  • the polymerization is carried out in the presence of the previously described Ziegler-Natta catalyst.
  • step a) Hydrogen is fed in an amount depending on the specific catalyst used and, in particular, suitable to obtain in step a) an ethylene polymer with a melt flow index MIE of 8 g/10 min. or higher.
  • MIE melt flow index
  • step a) the hydrogen/ethylene molar ratio is indicatively from 1 to 4, the amount of ethylene monomer being from 2 to 20% by volume, preferably from 5 tol5% by volume, based on the total volume of gas present in the polymerization reactor.
  • the remaining portion of the feeding mixture is represented by inert gases and one or more comonomers, if any. Inert gases which are necessary to dissipate the heat generated by the polymerization reaction are conveniently selected from nitrogen or saturated hydrocarbons, the most preferred being propane.
  • the operating temperature in the reactor of step a) is selected between 50 and 120°C, preferably between 65 and 100°C, while the operating pressure is between 0.5 and 10 MPa, preferably between 2.0 and 3.5 MPa.
  • the ethylene polymer obtained in step a) represents from 30 to 70% by weight of the total ethylene polymer produced in the overall process, i. e. in the first and second serially connected reactors.
  • step a) The ethylene polymer coming from step a) and the entrained gas are then passed through a solid/gas separation step, in order to prevent the gaseous mixture coming from the first polymerization reactor from entering the reactor of step b) (second gas-phase polymerization reactor). Said gaseous mixture can be recycled back to the first polymerization reactor, while the separated ethylene polymer is fed to the reactor of step b).
  • a suitable point of feeding of the polymer into the second reactor is on the connecting part between the downcomer and the riser, wherein the solid concentration is particularly low, so that the flow conditions are not negatively affected.
  • the operating temperature in step b) is in the range of 65 to 95°C, and the pressure is in the range of 1.5 to 4.0 MPa.
  • the second gas-phase reactor is aimed to produce a relatively high molecular weight ethylene copolymer by copolymerizing ethylene with one or more comonomers.
  • the reactor of step b) can be conveniently operated by establishing different conditions of monomers and hydrogen concentration within the riser and the downcomer.
  • step b) the gas mixture entraining the polymer particles and coming from the riser can be partially or totally prevented from entering the downcomer, so to obtain two different gas composition zones.
  • This can be achieved by feeding a gas and/or a liquid mixture into the downcomer through a line placed at a suitable point of the downcomer, preferably in the upper part thereof.
  • Said gas and/or liquid mixture should have a suitable composition, different from that of the gas mixture present in the riser.
  • the flow of said gas and/or liquid mixture can be regulated so that an upward flow of gas counter-current to the flow of the polymer particles is generated, particularly at the top thereof, acting as a barrier to the gas mixture entrained among the polymer particles coming from the riser.
  • One or more comonomers can be fed to the downcomer of step b), optionally together with ethylene, propane or other inert gases.
  • the hydrogen/ethylene molar ratio in the downcomer of step b) is comprised between 0.005 and 0.2, the ethylene concentration being comprised from 0.5 to 15%, preferably 0.5 - 10%, by volume, the comonomer concentration being comprised from 0.05 to 1.5 % by volume, based on the total volume of gas present in said downcomer.
  • the rest is propane or similar inert gases. Since a very low molar concentration of hydrogen is present in the downcomer, by carrying out the present process it is possible to bond a relatively high amount of comonomer to the high molecular weight polyethylene fraction.
  • the concentration of said comonomer drops to a range of 0.02 to 1.2 % by volume, based on the total volume of gas present in said riser.
  • the comonomer content is controlled in order to obtain the desired density of the final polyethylene.
  • the hydrogen/ethylene molar ratio is in the range of 0.01 to 0.5, the ethylene concentration being comprised between 5 and 20 % by volume based on the total volume of gas present in said riser.
  • the rest is propane or other inert gases.
  • contacted it is meant that the precursor polyethylene composition (I) and the radical initiator are mixed together and reacted with each other.
  • the said radical initiator is preferably selected from organic peroxides.
  • organic peroxides are organic monoperoxides and/or organic diperoxides. These organic monoperoxides and diperoxides may have a half-life of 1 hour at a temperature in the range of about 125°C to about 145°C, alternatively in the range of about 130°C to about 140°C, alternatively in the range of about 132°C to about 136°C. Further alternatives include organic peroxides having a half-life of 0.1 hour at a temperature in the range of about 145°C to 165°C, or in the range of about 150°C to about 160°C, or in the range of about 154°C to 158°C.
  • the organic peroxide may have a molecular weight in the range of about 175 g/mol to about 375 g/mol, alternatively in the range of about 200 g/mol to about 350 g/mol. Mixtures of two or more peroxides can be used if desired.
  • Suitable organic peroxides include, but are not limited to, dicumyl peroxide, di- tert-butyl peroxide, tert-butylperoxybenzoate, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,
  • the organic peroxide is 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane
  • the organic peroxide is employed in form of a polyolefin mixture, which is preferably prepared by adding the organic peroxide in pure form or as a solution in a diluent like a hydrocarbon to a polyolefin powder.
  • Preferred polyolefin mixtures have a content of the organic peroxide in the polyolefin mixture in the range from 0.5 to 25 wt.%, preferably from 1 to 20 wt.%, and more preferably from 2 to 10 wt.%.
  • the amount of added organic peroxide corresponds to a content of initiator in the precursor polyethylene composition (I) from 10 to 100 ppm by weight, more preferably from 15 to 90 ppm by weight, and in particular from 15 to 80 ppm by weight or from 15 to 50 ppm by weight.
  • the contact with the radical initiator can be carried out by any means and under the conditions known in the art to be effective for radical initiated reactions in olefin polymers. [0127] It is known that such reactions can be run in the conventional apparatuses generally used for processing polymers in the molten state.
  • the polyethylene composition of the present disclosure can be prepared by contacting the precursor polyethylene composition (I) and the radical initiator in an extruder device.
  • Suitable extruder devices are extruders or continuous mixers. These extruders or mixers can be single- or two-stage machines which melt and homogenize the polyethylene composition. Examples of extruders are pin-type extruders, planetary extruders or corotating disk processors. Other possibilities are combinations of mixers with discharge screws and/or gear pumps.
  • Preferred extruders are screw extruders and in particular extruders constructed as twin-screw machine.
  • twin-screw extruders and continuous mixers with discharge elements and especially to continuous mixers with counter rotating twin rotor or the extruder device comprises at least one co-rotating twin screw extruder.
  • Machinery of this type is conventional in the plastics industry and is manufactured by, for example, Coperion GmbH, Stuttgart, Germany; KraussMaffei Berstorff GmbH, Hannover, Germany; The Japan Steel Works LTD., Tokyo, Japan; Farrel Corporation, Ansonia, USA; or Kobe Steel, Ltd., Kobe, Japan.
  • Suitable extruder devices are further usually equipped with units for pelletizing the melt, such as underwater pelletizers.
  • the contact and reaction temperature is preferably in the range of from 180 to 350 °C, in particular from 180 to 300°C, and is generally equal to or higher than the decomposition temperature of the radical initiator.
  • the contact and reaction time is preferably several times the initiator's half-life. This provides a substantially complete reaction and minimizes the possibility of undesirable initiator residues in the polyethylene composition. Although low levels of undecomposed initiator are not detrimental, the presence of significant amounts of unreacted initiator can result in the formation of gels and other undesirable effects during subsequent processing of the polyethylene composition.
  • one or more additives can be fed to the polyethylene composition.
  • Feeding of these additives may occur before, during or after contacting the precursor polyethylene composition (I) with the radical initiator.
  • additives are common in the art. Suitable types of additives for preparing polyethylene compositions are, for example, antioxidants, melt stabilizers, light stabilizers, acid scavengers, lubricants, processing aids, antiblocking agents, slip agents, antistatic agents, antifogging agents, pigments or dyes, nucleating agents, flame retardants or fillers. It is common that several additives are added. The multiple additives can be different types of additives. It is however also possible that several representatives of one type of additives are added to the polyethylene composition. Additives of all these types are generally commercially available and are described, for example, in Hans Zweifel, Plastics Additives Handbook, 5th Edition, Kunststoff, 2001.
  • the solvent was vacuum distilled under Nitrogen and was stabilized with 0.025% by weight of 2, 6-di-tert-butyl-4-m ethylphenol.
  • the flowrate used was 1 ml/min, the injection was 500pl and polymer concentration was in the range of 0.01% ⁇ cone. ⁇ 0.05% w/w.
  • the molecular weight calibration was established by using monodisperse polystyrene (PS) standards from Polymer Laboratories (now Agilent Technologies, Reifenberger Str. 130, 71034 Boeblingen, Germany)) in the range from 580g/mol up to 11600000g/mol and additionally with Hexadecane.
  • PS monodisperse polystyrene
  • the calibration curve was then adapted to Polyethylene (PE) by means of the Universal Calibration method (Benoit H., Rempp P. and Grubisic Z., & in J. Polymer Sci., Phys. Ed., 5, 753(1967)).
  • Data recording, calibration and calculation was carried out using NTGPC_Control_V6.02.03 and NTGPC V6.4.24 (hs GmbH, HauptstraBe 36, D-55437 Ober-Hilbersheim, Germany) respectively.
  • the LCB index corresponds to the branching factor g’, measured for a molecular weight of 10 6 g/mol.
  • the branching factor g’ which allows determining long-chain branches at high Mw, was measured by Gel Permeation Chromatography (GPC) coupled with MultiAngle Laser-Light Scattering (MALLS).
  • GPC Gel Permeation Chromatography
  • MALLS MultiAngle Laser-Light Scattering
  • the radius of gyration for each fraction eluted from the GPC (as described above but with a flow-rate of 0.6 ml/min and a column packed with 30pm particles) is measured by analyzing the light scattering at the different angles with the MALLS (detector Wyatt Dawn EOS, Wyatt Technology, Santa Barbara, Calif.).
  • a laser source of 120mW of wavelength 658nm was used.
  • the specific index of refraction was taken as 0.104 ml/g.
  • Data evaluation was done with Wyatt ASTRA 4.7.3 and CORONA 1.4 software.
  • the LCB Index is determined as described in the following.
  • the ⁇ Rg 2 >unear ref.M is calculated by the established relation between radius-of- gyration and molecular weight for a linear polymer in solution (Zimm and Stockmayer WH 1949)) and confirmed by measuring a linear PE reference with the same apparatus and methodology described.
  • Samples were melt-pressed for 4 min under 200 °C and 200 bar into plates of 1mm thickness.
  • Disc specimens of a diameter of 25 mm were stamped and inserted in the rheometer, which was pre-heated at 190 °C.
  • the measurement can be performed using any rotational rheometer commercially available.
  • the Anton Paar MCR 300 was utilized, with a plate-plate geometry.
  • the value of the latter at an applied frequency co of 0.02 rad/s is the qo.02.
  • ER is determined by the method of R. Shroff and H. Mavridis, "New Measures of Poly dispersity from Rheological Data on Polymer Melts," J. Applied Polymer Science 57 (1995) 1605 (see also U.S. Pat. No. 5,534,472 at Column 10, lines 20-30). It is calculated from:
  • the determination of ER involves extrapolation.
  • the ER values calculated then will depend on the degree on nonlinearity in the log G' versus log G" plot.
  • the temperature, plate diameter and frequency range are selected such that, within the resolution of the rheometer, the lowest G" value is close to or less than 5,000 dyne/cm 2 .
  • HMWcopo High Molecular Weight Copolymer
  • HMWCOPO (qo.02 X tmaxDSc)/(10 A 5) [0154] It is decreasing with increasing potential of easy processing (low melt- viscosity) and fast crystallization of the polymer. It is also a description and quantification of the amount of high molecular weight fraction, correlating to the melt complex shear viscosity qo.02 at the frequency of 0.02 rad/s, measured as above described, and the amount of incorporated comonomer which delays the crystallization, as quantified by the maximum heat flow time for quiescent crystallization, tmaxDsc.
  • melt viscosity qo.02 value is multiplied by the tmaxDsc value and the product is normalized by a factor of 100000 (10 A 5).
  • the extrudate is cut (by an automatic cutting device from Gbttfert) at a distance of 150 mm from the die-exit, at the moment the piston reaches a position of 96 mm from the dieinlet.
  • the extrudate diameter is measured with the laser-diod at a distance of 78 mm from the die-exit, as a function of time.
  • the maximum value corresponds to the Dextrudate.
  • the swellratio is determined from the calculation:
  • Ddie is the corresponding diameter at the die exit, measured with the laser- diod.
  • FNCT full notch creep test
  • the environmental stress cracking resistance of polymer samples was determined in accordance to international standard ISO 16770 (FNCT) in aqueous surfactant solution. From the polymer sample a compression moulded 10 mm thick sheet has been prepared. The bars with squared cross section (10x10x100 mm) are notched using a razor blade on four sides perpendicularly to the stress direction. A notching device described in M. Fleissner in Kunststoffe 77 (1987), pp. 45 is used for the sharp notch with a depth of 1.6 mm.
  • the load applied is calculated from tensile force divided by the initial ligament area.
  • For FNCT specimen: 10x10 mm 2 - 4 times of trapezoid notch area 46.24 mm 2 (the remaining cross-section for the failure process / crack propagation).
  • the test specimen is loaded with standard condition suggested by the ISO 16770 with constant load of 6 MPa at 50°C in a 2% (by weight) water solution of non-ionic surfactant ARKOPAL N100. Time until rupture of test specimen is detected.
  • Weight swell was determined by adjusting the bottle weight to the desired amount, 90 g, with the reference resin Petrothene LR732002 and then comparing to the weight of a bottle of the resin being examined, produced under the same machine parameters.
  • test bottle is depicted in Figure 2.
  • WB is the weight of the tested bottle, in grams.
  • Diameter swell was determined by measuring the length of the flash on the bottle via graduated markings, from top (including the protruding top flash) down to and along the bottle handle at the same bottle weight as the reference resin, namely 90 g. The mold relative to the parison was adjusted so that the reference resin top flash edge fell on the 9 cm mark on the handle.
  • Screw speed 370 rpm (adjusted to adjust parison tail length);
  • the said reference resin Petrothene LR732002 is an ethylene polymer produced with a Cr catalyst, having FNCT 6 MPa / 50°C, measured as previously described, of about 0.4 hours.
  • the diameter swell was considered satisfactory when falling within the range of 8 to 10 cm.
  • the Film measurement of gels was carried out on an OCS extruder type ME 202008-V3 with 20 mm screw diameter and a screw length of 25 D with a slit die width of 150 mm.
  • the cast line is equipped with a chill roll and winder (model OCS CR-9).
  • the optical equipment consists of a OSC film surface analyzer camera, model FTA-100 (flash camera system) with a resolution of 26 pm x 26 pm. After purging the resin first for 1 hour to stabilize the extrusion conditions, inspection and value recording take place for 30 minutes afterwards.
  • the resin was extruded at 220°C with a take-off speed of ca. 2.7 m/min to generate a film with thickness 50 pm.
  • the chill roll temperature was 70°C.
  • the comonomer content is determined by means of IR in accordance with ASTM D 6248 98, using an FT-IR spectrometer Tensor 27 from Bruker, calibrated with a chemometric model for determining butyl- side-chains in PE for hexene as comonomer. The result is compared to the estimated comonomer content derived from the mass-balance of the polymerization process and was found to be in agreement.
  • the polymerization catalyst was prepared as follows.
  • a magnesium chloride and alcohol adduct containing about 3 mols of alcohol was prepared following the method described in example 2 of USP 4,399,054, but working at a velocity of 2000 RPM instead of 10000 RPM.
  • the so obtained adduct was dealcoholated up to an amount of alcohol of 25% wt via a thermal treatment, under nitrogen stream, over a temperature range of 50-150°C.
  • the whole content was filtered and washed three times with hexane at a temperature of 30 °C (100 g/1). After drying the resulting pre-polymerized catalyst (A) was analyzed and found to contain 55% wt of polypropylene, 2.0% wt Ti, 9.85% wt Mg and 0.31% wt Al. [0188] About 100 g of the solid prepolymerized catalyst prepared as described above were charged in a glass reactor purged with nitrogen and slurried with 1.0 L of heptane at 50°C.
  • EAA ethylacetate
  • CE tetrahydrofuran
  • a polyethylene was prepared in a cascade of a fluidized-bed reactor and a multizone circulating reactor having two interconnected reaction zones as shown in the drawing.
  • ethylene was polymerized in the presence of propane as inert diluent using hydrogen as molecular weight regulator. 47.5 kg/h of ethylene, 158 g/h of hydrogen and 11 kg/h of propane were fed to fluidized-bed reactor (1) via line 3. No comonomer was added. The polymerization was carried out at a temperature of 80°C and a pressure of 3.0 MPa. The selected feed rates resulted in an ethylene concentration in the reactor of 10.9 vol.-% and a molar ratio of hydrogen/ethylene in the reactor of 2.6.
  • the polyethylene obtained in fluidized-bed reactor (1) had a MIE of 74 g/10 min and a density of 0.967 g/cm 3 .
  • the polyethylene obtained in fluidized-bed reactor (1) was continuously transferred to multizone circulating reactor (MZCR), which was operated at a pressure of 2.6 MPa and a temperature of 85°C measured at the gas exit from reactor.
  • the riser (4) has an internal diameter of 200 mm and a length of 19 m.
  • the downcomer (5) has a total length of 18 m, an upper part of 5 m with an internal diameter of 300 mm and a lower part of 13 m with an internal diameter of 150 mm.
  • the second reactor was operated by establishing different conditions of monomers and hydrogen concentration within the riser (4) and the downcomer (5).
  • the final polymer was discontinuously discharged via line 18.
  • the first reactor produced around 50 % by weight (split wt %) of the total amount of the final polyethylene resin produced by both first and second reactors.
  • the obtained precursor polyethylene composition (I) had a final MIF of 30.6 g/10 min.
  • the obtained density was 0.956 g/cm 3 .
  • the comonomer (hexene-1) amount was of about 0.40 % by weight.
  • Irganox 1010® is 2,2-bis[3-[,5-bis(l,l-dimethylethyl)-4-hydroxyphenyl)-l- oxopropoxy]methyl]-l,3-propanediyl-3,5-bis(l,l-dimethylethyl)-4-hydroxybenzene- propanoate, supplied by BASF SE, Ludwigshafen, Germany.
  • Irgafos 168® is tris (2,4-di-tert-butylphenyl) phosphite, marketed by Ciba Geigy.
  • the polymer powder and said additives were introduced to the inlet of the mixer at a rate of 170 kg/h and a screw speed of 800 rpm.
  • a throttling gate which was adjusted to a position to get a temperature of 220°C in front of the gate.
  • a gear pump which was set at 0.1 MPa (1.0 bar) suction pressure.
  • Example 1 A portion of the polymer powder of Example 1 (as polymerized) was extruded with 1000 ppm Ca-Stearate, 800 ppm Irganox 1010, 1600 ppm Irgafos 168 and 267 ppm of Pergaprop 7.5 PP (all ppm by weight).
  • Pergaprop 7.5 PP® is a 7.5 wt.% mixture of 2,5-dimethyl-2,5-di-(tert.-butyl- peroxy)-hexane with polypropylene, supplied by PERGAN GmbH, Bocholt, Germany.
  • the first reactor produced around 50.5 % by weight (split wt %) of the total amount of the final polyethylene resin produced by both first and second reactors.
  • the obtained precursor polyethylene composition (I) had a final MIF of 36.2 g/10 min.
  • the obtained density was 0.957 g/cm 3 .
  • a portion of the obtained polymer powder (as polymerized, i.e. without additives) was extruded with 1000 ppm Ca-Stearate, 800 ppm Irganox 1010 and 1600 ppm Irgafos 168 (all ppm by weight).
  • Example 3 A portion of the polymer powder of Example 3 (as polymerized) was extruded with 1000 ppm Ca-Stearate, 800 ppm Irganox 1010, 1600 ppm Irgafos 168 and 267 ppm of Pergaprop 7.5 PP (all ppm by weight).

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Abstract

Composition de polyéthylène particulièrement appropriée pour la production d'articles creux moulés par soufflage, possédant les caractéristiques suivantes : 1) une masse volumique de plus de 0,955 à 0,965 g/cm3 ; 2) un rapport MIF/MIE de 60 à 125 ; 3) un MIF de 15 à 40 g/10 min. ; 4) des valeurs ER de 3,0 à 5,5 ; 5) η0,02 égal ou inférieur à 150 000 Pa.s.
PCT/EP2023/075131 2022-09-15 2023-09-13 Composition de polyéthylène pour moulage par soufflage possédant un comportement de gonflement amélioré WO2024056727A1 (fr)

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