Process for the Preparation of a Catalyst Component for the Polymerization of an Olefin

• US 20080312389A1
• Filed: 11/11/2005
• Published: 12/18/2008
• Est. Priority Date: 11/26/2004
• Status: Active Grant

• Current Assignee: Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Original Assignee: Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Inventors: Zakharov, Vladimir Aleksandrovich, Ramjoie, Yves Johann Elizabeth, Vlaar, Mark, Sergeev, Sergei Andreevich, Bukatov, Gennadii Dimitrievich
• Granted Patent: US 7,947,788 B2
• Time in Patent Office: Days
• US Class Current: 526/97
• CPC Class Codes: C08F 10/00 Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 2500/18 Bulk density
• CPC Class Codes: C08F 4/651 Pretreating with non-metals or metal-free compounds
• CPC Class Codes: C08F 4/6541 and metals of C08F4/64 or compounds thereof

Abstract

The invention is directed to a process for the preparation of a catalyst component wherein a compound with formula Mg(OAlk)_xCl_y wherein x is larger than 0 and smaller than 2, y equals 2-x and each Alk, independently represents an alkyl group, is contacted with a titanium tetraalkoxide and/or an alcohol in the presence of an inert dispersant to give an intermediate reaction product and wherein the intermediate reaction product is contacted with titanium tetrachloride in the presence of an internal donor.

The invention also relates to a polymerization catalyst comprising the catalyst component and furthermore the invention relates to the polymerization of an olefin in the presence of the polymerization catalyst comprising the catalyst component.

Claims

1. A process for the preparation of a polymerization catalyst component wherein a compound with formula Mg(OAlk)_xCl_y wherein x is larger than 0 and smaller than 2, y equals 2-x and each Alk, independently, represents an alkyl group, is contacted with a titanium tetraalkoxide and/or an alcohol in the presence of an inert dispersant to give an intermediate reaction product and wherein the intermediate reaction product is contacted with titanium tetrachloride in the presence of an internal donor.

2. The process according to claim 1 wherein the compound with formula Mg(OAlk)_xCl_y is contacted with a titanium tetraalkoxide in the presence of the inert dispersant to give an intermediate reaction product.

3. The process according to claim 1 wherein at least one of the Alk-groups is an ethyl group.

4. The process according to claim 1 wherein at least one of the alkoxide groups in titanium tetraalkoxide is an ethoxy group.

5. The process according to claim 4, wherein the titanium alkoxide is titanium tetraethoxide.

6. The process according to claim 1 wherein the dispersant is heptane.

7. The process according to claim 1 wherein the compound with formula Mg(OAlk)_xCl_y is contacted with the titanium tetraalkoxide and/or alcohol at a temperature in the range of −

10°

C. to 50°

C.

8. The process according to claim 1 wherein the molar ratio of titanium tetraalkoxide to Mg(OAlk)_xCl_y is between 0.02 and 0.5.

9. The process according to claim 1 wherein the alcohol is ethanol.

10. The process according to claim 1 wherein the molar ratio of alcohol to Mg(OAlk)_xCl_y is between 0.02 and 0.5.

11. The process according to claim 1 wherein a compound with formula Mg(OAlk)_xCl_y is prepared in a process wherein a metallic magnesium is contacted with an organic halide RX, where R is an organic group containing up to 20 carbon atoms and X is a halide, to form a resulting dissolved first reaction product, whereupon the resulting dissolved first reaction product is separated from solid residual products and whereafter, an alkoxy group or aryloxy group containing silane compound is added to the resulting dissolved first reaction product, whereupon a precipitate is formed and purified to obtain the compound with formula Mg(OAlk)_xCl_y.

12. The process according to claim 11, wherein the alkoxy group or aryloxy group containing silane compound and the resulting dissolved first reaction product are introduced simultaneously to a mixing device and wherein the mixing device is a static mixer.

13. A polymerization catalyst comprising a catalyst component comprising a reaction product of the following in the order of:

a) a compound with formula Mg(OAlk)_xCl_y wherein x is larger than 0 and smaller than 2, y equals 2-x and each Alk, independently, represents an alkyl group,

b) a titanium tetraalkoxide and/or an alcohol, and

c) an inert dispersant,

and

d) titanium tetrachloride, and

e) an internal donor

and a co catalyst.

14. The catalyst according to claim 13 wherein the co catalyst is an organometallic compound containing a metal from group 1, 2, 12 or 13 of the Periodic System of the Elements.

15. A process for preparation of polyolefins comprising polymerization of one or more olefins in the presence of a polymerization catalyst comprising a catalyst component comprising a reaction product of the following in the order of:

a) a compound with formula Mg(OAlk)_xCl_y wherein x is larger than 0 and smaller than 2, y equals 2-x and each Alk, independently, represents an alkyl group,

b) a titanium tetraalkoxide and/or an alcohol, and

c) an inert dispersant,

and

d) titanium tetrachloride, and

e) an internal donor;

and a co catalyst.

16. The process according to claim 15 wherein the olefin is propylene or a mixture of propylene and ethylene.