Catalyst composition for polymerization of olefins

• US 9,663,596 B2
• Filed: 01/28/2014
• Issued: 05/30/2017
• Est. Priority Date: 01/31/2013
• Status: Active Grant

• Current Assignee: Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Original Assignee: Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Inventors: Taftaf, Mansour, Sainani, Jaiprakash Brijlal, Zakharov, Vladimir Aleksandrovich, Bukatov, Gennadii Dimitrievich, Patel, Vimalkumar Mahendrabhai, Sergeev, Sergei Andreevich, Batinas-Geurts, Aurora Alexandra, Zuideveld, Martin Alexander
• Primary Examiner(s): Branch, Catherine S
• Application Number:
  US14/762,279
• Publication Number:
  US 20150353656A1
• Time in Patent Office: 1,218 Days
• Field of Search: None
• CPC Class Codes: C07C 233/18 having the carbon atom of the carboxamide group bound to a hydrogen atom or to a carbon atom of an acyclic saturated carbon skeleton
• CPC Class Codes: C07C 233/23 with the substituted hydrocarbon radical bound to the nitrogen atom of the carboxamide group by a carbon atom of a ring other than a six-membered aromatic ring
• CPC Class Codes: C07C 233/69 of an acyclic saturated carbon skeleton
• CPC Class Codes: C07C 2601/14 The ring being saturated
• 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 10/06 Propene
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 2410/06 Catalyst characterized by its size
• CPC Class Codes: C08F 2500/04 Broad molecular weight distribution, i.e. Mw/Mn > 6
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 2500/24 Polymer with special particle form or size
• CPC Class Codes: C08F 4/649 organic
• CPC Class Codes: C08F 4/651 Pretreating with non-metals or metal-free compounds
• CPC Class Codes: C08F 4/6546 organo-magnesium compounds
• CPC Class Codes: C08F 4/655 with aluminium or compounds thereof
• CPC Class Codes: C08F 4/6565 and magnesium or compounds thereof

Abstract

A catalyst composition comprising a monoester, the compound represented by formula (I) as an internal electron donor, and optionally an additional internal electron donor selected from a group consisting of diesters and diethers,

wherein: R₁, R₂, R₃, R₄, R₅ and R₆ are hydrogen, straight, branched and cyclic alkyl having at most 20 carbon atoms and aromatic substituted and unsubstituted hydrocarbyl having 6 to 20 carbon atoms, R₇ is a straight, branched and cyclic alkyl having at most 20 carbon atoms and aromatic substituted and unsubstituted hydrocarbyl having 6 to 20 carbon atoms, and R₈ is an aromatic substituted and unsubstituted hydrocarbyl having 6 to 20 carbon atoms. Also described is a process for preparing the polymerization catalyst composition, a polymerization catalyst system comprising the catalyst composition, a co-catalyst and optionally an external electron donor; and use of the catalyst system for polymerization of olefins.

Claims

1. A catalyst composition for polymerization of olefins comprising a monoester and an internal electron donor represented by formula (I),

2. The catalyst composition according to claim 1, wherein R₁, R₂, R₃, R₄, R₅ and R₆ are independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, isopropyl, butyl, tert-butyl, phenyl, trifluoromethyl and halophenyl.

3. The catalyst composition according claim 1, wherein when one of R₃ and R₄ has at least one carbon atom then the other one of R₃ and R₄ is hydrogen and wherein when one of R₅ and R₆ has at least one carbon atom then the other one of R₅ and R₆ is a hydrogen atom.

4. The catalyst composition according to claim 1, wherein R₇ is selected from a group consisting of methyl, ethyl, propyl, isopropyl, butyl, tert-butyl, phenyl, benzyl, substituted benzyl and halophenyl and/or wherein R₈ is substituted or unsubstituted phenyl, benzyl, naphthyl, ortho-tolyl, para-tolyl or anisol.

5. The catalyst composition according to claim 1, wherein the monoester is an acetate or a benzoate.

6. The catalyst composition according to claim 1, comprising a magnesium-containing support, a halogen-containing titanium compound, said monoester and said internal electron donor according to formula (I).

7. The catalyst composition according to claim 1, further comprising a second additional internal electron donor, wherein the second electron donor is selected from the group consisting of diesters and diethers.

8. The catalyst composition according to claim 6, further comprising the second internal electron donor, wherein the second internal electron donor is selected from the group consisting of diesters and diethers, wherein the molar ratio of the additional internal electron donor to magnesium of said magnesium-containing support is between 0.02 and 0.15.

12. A polymerization catalyst system comprising the catalyst composition according to claim 1, a co-catalyst and optionally an external electron donor.

13. A process of making a polyolefin comprising contacting an olefin with the catalyst system according to claim 12.

9. A process for preparing a catalyst composition, comprising contacting a magnesium-containing support with a halogen-containing titanium compound, a monoester, a first internal electron donor represented by formula (I), and optionally a second internal electron donor selected from a group consisting of diesters and diethers,

10. The process according to claim 9, which comprises:

i) contacting a compound R⁹_zMgX_2-z wherein R⁹ is aromatic, aliphatic or cyclo-aliphatic group containing 1 to 20 carbon atoms, X is a halide, and z is in a range of larger than 0 and smaller than 2, with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product;

ii) contacting the first intermediate reaction product with at least one activating compound selected from the group of electron donors and compounds of formula M(OR¹⁰)_v-w(OR¹¹)_w wherein M is Ti, Zr, Hf, Al or Si, or M(OR¹⁰)_v-w(R¹¹)_w wherein M is Si, each R¹⁰ and R¹¹, independently, represent an alkyl, alkenyl or aryl group, v is the valency of M, v being either 3 or 4, and w is smaller than v to give a second intermediate reaction product; and

iii) contacting the second intermediate reaction product with a halogen-containing Ti-compound, the monoester, the compound represented by formula (I) as the first internal electron donor, and optionally the diester or diether as the second internal electron donor.

11. A catalyst composition manufactured by the process according to claim 9.

14. A catalyst composition for the polymerization of olefins, comprising

an acetate or benzoate monoester;

a compound represented by formula (I) as a first internal electron donor

15. The catalyst composition of claim 14, wherein

the monoester is ethyl acetate, amyl acetate or ethyl benzoate;

R₁ and R₂ are each a hydrogen atom; and

when one of R₃ and R₄ has at least one carbon atom then the other one of R₃ and R₄ is hydrogen and wherein when R₅ and R₆ has at least one carbon atom then the other one of R₅ and R₆ is a hydrogen atom.

16. A process for the manufacture of the catalyst composition of claim 14, which comprises:

i) contacting a compound R⁹_zMgX_2-z wherein R⁹ is aromatic, aliphatic or cyclo-aliphatic group containing 1 to 20 carbon atoms, X is a halide, and z is in a range of larger than 0 and smaller than 2, with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product;

ii) contacting the first intermediate reaction product with at least one activating compound selected from the group of electron donors and a compound of the formula M(OR¹⁰)_v-w(R¹¹)_w wherein M is Si, each R¹⁰ and R¹¹, independently, represent an alkyl, alkenyl or aryl group, v is the valency of M, v being either 3 or 4, and w is smaller than v to give a second intermediate reaction product; and

iii) contacting the second intermediate reaction product with a halogen-containing Ti-compound, the monoester, the compound represented by formula (I) as the first internal electron donor, and optionally the second internal electron donor.

17. A polymerization catalyst system comprising the catalyst composition according to claim 14, a co-catalyst, and optionally an external electron donor.

18. A process of making a polyolefin comprising contacting an olefin with the catalyst system according to claim 17.