High activity polyethylene catalyst prepared from an alcohol and silicon tetrachloride
First Claim
1. A catalyst composition for copolymerization of ethylene with an alpha-olefin, to produce a resin product of narrow molecular weight distribution, and having a density of less than 0.94 g/cc;
- wherein the catalyst composition is prepared by a process which comprises the steps of;
(i) contacting a solid, porous carrier having reactive OH groups in a non-polar liquid with dibutylmagnesium to form a product of step (i) which contains said carrier and incorporated therein a source of magnesium, wherein said dibutylmagnesium is soluble in said non-polar liquid;
wherein, the ratio of the number of moles of said dibutylmagnesium to the number of moles of said OH groups is from about 1.1 to about 2.5;
(ii) introducing into the liquid containing said product of step (i) a mixture of SiCl4 and an alcohol R"OH in which R" is selected from the group consisting of methyl, ethyl, propyl, n-butyl, pentyl, and n-octyl, thereby to form a slurry of step (ii) wherein the mixture has a molar ratio of R"OH to SiCl4 of 2.00 to 6.00;
wherein the molar ratio of SiCl4 to Mg is 0.40 to 1.40; and
wherein the molar ratio of R"OH to Mg is at least about 1.32.(iii) contacting said slurry of step (ii) with at least one transition metal compound in a non-polar liquid medium, the number of moles of said transition metal compound being in excess of the number of moles of OH groups on said carrier prior to reaction with said dibutylmagnesium in step (i), said transition metal compound being soluble in said non-polar liquid, and said dibutylmagnesium contacted carrier being substantially insoluble in said liquid medium, whereby a reacted form of the transition metal becomes supported on said carrier to form a step (iii) precursor; and
(iv) contacting the step (iii) precursor with an activating amount of trialkylaluminum R'"'"'3 Al, in which R'"'"' is an alkyl group of 1 to 10 carbon atoms.
0 Assignments
0 Petitions
Accused Products
Abstract
A catalyst composition for producing linear low density polyethylene with relatively narrower molecular weight distributions is described. The catalyst is formed by treating silica having reactive OH groups with a dialkylmagnesium in a solvent for said dialkylmagnesium; then adding to said magnesium-containing support a mixture of ROH and SiCl4 to form an intermediate which is subsequently treated with a transition metal to form a transition metal-containing intermediate, the catalyst precursor. The catalyst precursor is activated with a trialkylaluminum compound.
-
Citations
38 Claims
-
1. A catalyst composition for copolymerization of ethylene with an alpha-olefin, to produce a resin product of narrow molecular weight distribution, and having a density of less than 0.94 g/cc;
- wherein the catalyst composition is prepared by a process which comprises the steps of;
(i) contacting a solid, porous carrier having reactive OH groups in a non-polar liquid with dibutylmagnesium to form a product of step (i) which contains said carrier and incorporated therein a source of magnesium, wherein said dibutylmagnesium is soluble in said non-polar liquid;
wherein, the ratio of the number of moles of said dibutylmagnesium to the number of moles of said OH groups is from about 1.1 to about 2.5;(ii) introducing into the liquid containing said product of step (i) a mixture of SiCl4 and an alcohol R"OH in which R" is selected from the group consisting of methyl, ethyl, propyl, n-butyl, pentyl, and n-octyl, thereby to form a slurry of step (ii) wherein the mixture has a molar ratio of R"OH to SiCl4 of 2.00 to 6.00;
wherein the molar ratio of SiCl4 to Mg is 0.40 to 1.40; and
wherein the molar ratio of R"OH to Mg is at least about 1.32.(iii) contacting said slurry of step (ii) with at least one transition metal compound in a non-polar liquid medium, the number of moles of said transition metal compound being in excess of the number of moles of OH groups on said carrier prior to reaction with said dibutylmagnesium in step (i), said transition metal compound being soluble in said non-polar liquid, and said dibutylmagnesium contacted carrier being substantially insoluble in said liquid medium, whereby a reacted form of the transition metal becomes supported on said carrier to form a step (iii) precursor; and (iv) contacting the step (iii) precursor with an activating amount of trialkylaluminum R'"'"'3 Al, in which R'"'"' is an alkyl group of 1 to 10 carbon atoms. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 25, 26, 30, 31, 32, 33, 35, 36)
- wherein the catalyst composition is prepared by a process which comprises the steps of;
-
12. A catalyst composition for copolymerization of ethylene with an alpha-olefin, to produce a resin product of narrow molecular weight distribution, wherein the catalyst is prepared by a process which comprises the steps of:
-
contacting a solid, porous carrier having reactive OH groups in a non-polar liquid with an organomagnesium compound which has the empirical formula
space="preserve" listing-type="equation">R.sub.m MgR'"'"'.sub.nwhere R and R'"'"' are the same or different C4 -C8 alkyl groups, and m and n are each 0, 1 or 2, providing that m+n=2, to form a product of step (i) which contains said carrier and incorporated therein a source of magnesium, wherein said organomagnesium compound is soluble in said non-polar liquid;
wherein, the ratio of the number of moles of said organomagnesium compound to the number of moles said OH groups is from about 1.1 to about 2.5(ii) introducing into the liquid containing said product of step (i) a mixture of R"OH wherein R" is selected from the group consisting of methyl, ethyl, propyl, n-butyl, pentyl, and n-octyl, and SiCl4 to form a slurry of step (ii) wherein the mixture is characterized by a molar ratio of R"OH to SiCl4 ranging from 2.00 to 6.00;
wherein the molar ratio of SiCl4 to Mg is 0.40 to 1.40; and
wherein the molar ratio of R"OH to Mg is at least about 1.32(iii) contacting said slurry of step (ii) with at least one transition metal compound in a non-polar liquid medium, the number of moles of said transition metal compound being in excess of the number of moles of OH groups on said carrier prior to reaction with said organomagnesium compound in step (i), said transition metal compound being soluble in said non-polar liquid, and said organomagnesium compound contacted carrier being substantially insoluble in said liquid medium, whereby a reacted form of the transition metal becomes supported on said carrier to form a step (iii) precursor; and (iv) contacting the step (iii) precursor with an activating amount of trialkylaluminum. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 27, 28, 29, 34, 37, 38)
-
Specification