CATALYST SYSTEM FOR POLYMERIZATION OF AN OLEFIN

• US 20160326280A1
• Filed: 12/19/2014
• Published: 11/10/2016
• Est. Priority Date: 12/20/2013
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia), Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Original Assignee: SABIC Global Technologies BV (Government of Saudi Arabia), Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Inventors: Smeets, Bobby Johannes Henricus Hubertus, Batinas-Geurts, Aurora Alexandra, Zuideveld, Martin Alexander
• Granted Patent: US 9,944,734 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C08F 10/06 Propene
• CPC Class Codes: C08F 210/06 Propene
• CPC Class Codes: C08F 210/16 Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 4/6465 containing silicium
• CPC Class Codes: C08F 4/6495 containing nitrogen
• CPC Class Codes: C08F 4/6565 and magnesium or compounds thereof

Abstract

The invention relates to a process for preparing a catalyst system suitable for olefin polymerization. The present invention further relates to a catalyst system obtainable by such process. In addition, the invention relates to a polyolefm. The invention also relates to ashaped article. The catalyst system comprises a procatalyst, a co-catalyst and optionally at least one external electron donor.

Claims

1. A process for preparing a catalyst system for olefin polymerization, said catalyst system comprising a procatalyst, a co-catalyst and optionally at least one external electron donor said process comprising:

A) providing said procatalyst obtained via a process comprising;

i) contacting a compound R⁴_zMgX⁴_2-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, being a solid Mg(OR¹)_xX¹_2-x, wherein;

R⁴ is the same as R¹ being a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, or alkylaryl groups, and one or more combinations thereof;

wherein said hydrocarbyl group is substituted or unsubstituted, and optionally comprises one or more heteroatoms;

X⁴ and X¹ are each independently selected from the group of consisting of fluoride (F⁻

), chloride (Cl⁻

), bromide (Br⁻

) or iodide (I⁻

);

z is in a range of larger than 0 and smaller than 2, being 0<

z<

2;

ii) optionally contacting the solid Mg(OR¹)_xX¹_2-x obtained in step i) with at least one activating compound selected from the group formed by activating electron donors and metal alkoxide compounds of formula M¹(OR²)_v-w(OR³)_w or M²(OR²)_v-w(R³)_w, to obtain a second intermediate product;

wherein;

M¹ is a metal selected from the group consisting of Ti, Zr, Hf, Al or Si;

M² is a metal being Si;

v is the valency of M¹ or M²;

R² and R³ are each a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof;

wherein said hydrocarbyl group is substituted or unsubstituted, and optionally comprises one or more heteroatoms;

iii) contacting the first or second intermediate reaction product, obtained respectively in step i) or ii), with a halogen-containing Ti-compound and an internal electron donor to obtain said procatalyst;

B) contacting said procatalyst with a co-catalyst; and

optionally at least one external donor;

characterized in that said internal and/or external electron donor is an N-containing donor.

2. The process according to claim 1, wherein the N-containing donor is selected from the group consisting of benzamides, di-alkylaminoalkyl-trialkoxysilanes, imidosilanes, alkylimidosilanes and aminobenzoates.

3. The process according to claim 1, wherein the N-containing internal donor is an aminobenzoate according to Formula XI:

4. The process according to claim 1,

wherein the N-containing internal and/or external donor is a di-alkylaminoalkyl-trialkoxysilane according to Formula C

(R⁹⁰)₂—

N-A-Si—

(OR⁹¹)₃  

 

Formula C

wherein each R⁹⁰ groups is independently selected from an alkyl having 1-10 carbon atoms, wherein each R⁹¹ group is independently selected from an alkyl having 1-10 carbon atoms, wherein A is a either a direct N—

Si bond, or an alkyl spacer selected from an alkyl having 1-10 carbon atoms, and/or

wherein the N-containing internal and/or external donor is an imidosilane according to formula I;

Si(L)_n(OR¹)_4-n  

 

Formula I

wherein;

Si is a silicon atom with valency 4+;

O is an oxygen atom with valency 2− and

O is bonded to Si via a silicon-oxygen bond;

n is 1, 2, 3 or 4;

R¹ is selected from the group consisting of linear, branched and cyclic alkyl groups having at most 20 carbon atoms and aromatic substituted and unsubstituted hydrocarbyl groups having 6 to 20 carbon atoms; and

L is a group represented by Formula II;

5. The process according to claim 3, wherein the N-containing internal donor is an aminobenzoate according to formula XI;

and the N-containing external donor is a di-alkylaminoalkyl-trialkoxysilane according to Formula C

(R⁹⁰)₂—

N-A-Si—

(OR³¹)₃  

 

Formula C

wherein each R⁹⁰ group is independently selected from an alkyl having 1-10 carbon atoms, wherein each R⁹¹ group is independently selected from an alkyl having 1-10 carbon atoms, wherein A is a either a direct N—

Si bond, or an alkyl spacer selected from an alkyl having 1-10 carbon atoms.

6. Process according to claim 1, wherein the process is essentially phthalate free.

7. Process according to claim 1, wherein the N-containing internal electron donor is activated by an activator wherein the activator is a benzamide according to formula X:

8. The process according to claim 7, wherein the benzamide according to formula X is present in the procatalyst in an amount from 0.1 to 4 wt. %.

9. A catalyst system obtained by the process of claim 1.

10. A process for the preparation of polyolefins, comprising contacting the catalyst system of claim 9 with an olefin, and optionally an external donor.

11. A polyolefin obtained by the process of claim 10.

12. A shaped article comprising the polyolefin of claim 11.

13. The process according to claim 1, wherein the N-containing internal electron donor is activated by an activator.

14. The process according to claim 13, wherein the activator is N,N-dimethylbenzamide.

15. The process according to claim 1, wherein

R⁴ and R¹ each have from 1 to 20 carbon atoms;

and

R² and R³ each have from 1 to 20 carbon atoms.

16. The process according to claim 3, wherein

R⁸³, R⁸⁴, R⁸⁵ and R⁸⁶ are independently selected from a group consisting of C₁-C₁₀ straight and branched alkyl and phenyl;

and

R⁸⁸ is selected from the group consisting of substituted or unsubstituted phenyl, benzyl, naphthyl, ortho-tolyl, para-tolyl or anisol group.

17. The process acccording to claim 3, wherein the N-containing internal donor is selected from the group consisting of 4-[benzoyl(methyl)amino]pentan-2-yl benzoate;

2,2,6,6-tetramethyl-5-(methylamino)heptan-3-ol dibenzoate;

4-[benzoyl (ethyl)amino]pentan-2-yl benzoate, 4-(methylamino)pentan-2-yl bis (4-methoxy)benzoate), 3-[benzoyl(cyclohexyl)amino]-1-phenylbutyl benzoate, 3-[benzoyl(propan-2-yl)amino]-1-phenylbutyl, 4-[benzoyl(methyl)amino]-1,1,1-trifluoropentan-2-yl, 3-(methylamino)-1,3-diphenylpropan-1-ol dibenzoate, 3-(methyl)amino-propan-1-ol dibenzoate;

3-(methyl)amino-2,2-dimethylpropan-1-ol dibenzoate, and 4-(methylamino)pentan-2-yl bis (4-methoxy)benzoate).

18. The process of of claim 4, wherein

the N-containing internal and/or external donor is diethylaminotriethoxysilane or diethylamino methyl triethoxysilane.

19. The process of of claim 17, wherein the N-containing external donor is diethylaminotriethoxysilane or diethylamino methyl triethoxysilane.

20. The process of claim 18, wherein the N-containing internal electron donor is activated by N,N-dimethylbenzamide.