Ethylene terpolymers and process for their preparation

A polymer of ethylene as a first component or monomer with at least one branched alpha olefin as a second component or monomer and at least one linear alpha olefin as a third component or monomer, and which has the following properties:

• a) a melt flow rate as measured according to ASTM D 1238 in the range of 0,01 to about 100 g/10 min;
• and/or
• b) a density as measured according to ASTM D 1505 in the range of about 0,835 to about 0,950;
• and/or
• c) when its hardness is plotted against its density, it conforms to the following equation:
• 545,4ρ−463,64<H<545,4ρ−447,3
• where ρ is the density of the polymer as measured according to ASTM D 1505 and H is the hardness of the polymer as measured according to ASTM D 2240, with the domain for which the equation is valid being:
• 0<H<60
• and
• 0,82<ρ<0,96

A polymer which is the reaction product of ethylene as a first component or monomer with at least one branched alpha olefin as a second component or monomer and at least one linear alpha olefin as a third component or monomer, and which has the following properties:

• a) a melt flow rate as measured according to ASTM D 1238 in the range of 0,01 to about 100 g/10 min;
• and/or
• b) a density as measured according to ASTM D 1505 in the range of about 0,835 to about 0,950;
• and/or
• c) when its hardness is plotted against its density, it conforms to the following equation:
• 545,4ρ−463,64<H<545,4ρ−447,3
• where ρ is the density of the polymer as measured according to ASTM D 1505 and H is the hardness of the polymer as measured according to ASTM D 2240, with the domain for which the equation is valid being:
• 0<H<60
• and
• 0,82<ρ<0,96

A terpolymer of ethylene as a first component or monomer with at least one branched alpha olefin as a second component or monomer and at least one linear alpha olefin as a third component or monomer, and which has the following properties:

• a) a melt flow rate as measured according to ASTM D 1238 in the range of 0,01 to about 100 g/10 min;
• and/or
• b) a density as measured according to ASTM D 1505 in the range of about 0,835 to about 0,950;
• and/or
• c) when its hardness is plotted against its density, it conforms to the following equation:
• 545,4ρ−463,64<H<545,4ρ−447,3
• where ρ is the density of the polymer as measured according to ASTM D 1505 and H is the hardness of the polymer as measured according to ASTM D 2240, with the domain for which the equation is valid being:
• 0<H<60
• and
• 0,82<ρ<0,96

A process for producing a polymer, which process comprises reacting at least ethylene as a first component or monomer, a branched alpha olefin as a second component or monomer, and a linear alpha olefin as a third component or monomer in one or more reaction zones, while maintaining the reaction zone(s) at a pressure between atmospheric pressure and 5000 kg/cm2, and at a temperature between ambient and 300° C., in the presence of a particular catalyst, or a catalyst system comprising a particular catalyst and a cocatalyst, with the particular catalyst being that obtained by:

• i) suspending partially anhydrous magnesium chloride in a highly purified hydrocarbon solvent to obtain a magnesium chloride slurry;
• ii) adding to the slurry at least one alcohol and one ether and stirring the mixture for a period of time to obtain a partially activated magnesium chloride;
• iii) adding thereto, in drop wise fashion, an alkyl aluminium compound, with the resultant mixture being ground to a smooth consistency and thereafter cooled to room temperature to obtain an activated magnesium chloride;
• iv) washing the activated magnesium chloride with a highly purified hydrocarbon solvent to obtain a washed activated magnesium chloride, which constitutes the support of the catalyst;
• v) adding a mixture of alcohols to the washed support, followed by stirring, to obtain an alcohol loaded support;
• vi) adding titanium tetrachloride to the alcohol loaded support and stirring the resultant mixture under reflux for a period of time to obtain a titanium loaded catalyst;
• and
• vii) cooling and then washing the titanium loaded catalyst with a highly purified hydrocarbon solvent, followed by drying and pulverising thereof to obtain the catalyst.

A process for producing a polymer, which process comprises reacting at least ethylene as a first component or monomer, with a branched alpha olefin as a second component or monomer, and with a linear alpha olefin as a third component or monomer, in one or more reaction zones, while maintaining the reaction zone(s) at a pressure between atmospheric pressure and 5000 kg/cm21 and at a temperature between ambient and 300° C., in the presence of a particular catalyst, or a catalyst system comprising a particular catalyst and a cocatalyst, with the particular catalyst being that obtained by:

• i) suspending partially anhydrous magnesium chloride in a highly purified hydrocarbon solvent to obtain a magnesium chloride slurry;
• ii) adding to the slurry at least one ether and stirring the mixture for a period of time to obtain a partially activated magnesium chloride;
• iii) filtering and washing the partially activated magnesium chloride slurry with a highly purified hydrocarbon solvent until no ether is detected in the washing liquid, to obtain a washed partially activated magnesium chloride;
• iv) adding thereto, in drop wise fashion, an alkyl aluminium compound followed by grinding to a smooth consistency and cooling to room temperature, to obtain an activated magnesium chloride;
• v) washing the activated magnesium chloride with a highly purified hydrocarbon solvent until no alkyl aluminium is detected in the washing liquid, to obtain a washed activated magnesium chloride, which constitutes the support of the catalyst;
• vi) adding a mixture of alcohols to the washed support, followed by stirring, to obtain an alcohol loaded support;
• vii) washing the alcohol loaded support with a highly purified hydrocarbon solvent, to obtain a washed alcohol loaded support;
• viii) adding titanium tetrachloride to the washed alcohol loaded support, and grinding it to a smooth consistency to obtain a titanium loaded catalyst;
• and
• ix) washing the titanium loaded catalyst with a highly purified hydrocarbon solvent until no titanium is detected in the washing liquid, to obtain the catalyst.

A process for producing a polymer, which process comprises reacting at least ethylene as a first component or monomer, with a branched alpha olefin as a second component or monomer and with a different branched alpha olefin as a third component or monomer, in one or more reaction zones, while maintaining the reaction zone(s) at a pressure between atmospheric pressure and 5000 kg/cm2, and at a temperature between ambient and 300° C., in the presence of a particular catalyst, or a catalyst system comprising a particular catalyst and a cocatalyst, wherein the particular catalyst is that obtained by:

• i) suspending partially anhydrous magnesium chloride in a highly purified hydrocarbon solvent to obtain a magnesium chloride slurry;
• ii) adding to the slurry at least one alcohol and one ether, and stirring the mixture for a period of time to obtain a partially activated magnesium chloride;
• iii) adding thereto, in drop wise fashion, an alkyl aluminium component, with the resultant mixture being ground to a smooth consistency, and thereafter cooled to room temperature, to obtain an activated magnesium chloride;
• iv) washing the activated magnesium chloride with a highly purified hydrocarbon solvent to obtain a washed activated magnesium chloride, which constitutes the support of the catalyst;
• v) adding a mixture of alcohols to the washed support, followed by stirring, to obtain an alcohol loaded support;
• vi) adding titanium tetrachloride to the alcohol loaded support and stirring the resultant mixture under reflux for a period of time to obtain a titanium loaded catalyst;
• and
• vii) cooling and then washing the titanium loaded catalyst with a highly purified hydrocarbon solvent, followed by drying and pulverising to obtain the catalyst.

A process for producing a polymer, which process comprises reacting at least ethylene as a first component or monomer, with a branched alpha olefin as a second component or monomer and with a different branched alpha olefin as a third component or monomer in one or more reaction zones, while maintaining the reaction zone(s) at a pressure between atmospheric pressure and 5000 kg/cm2, and at a temperature between ambient and 300° C., in the presence of a particular catalyst, or a catalyst system comprising a particular catalyst and a cocatalyst, with the particular catalyst being that obtained by:

• i) suspending partially anhydrous magnesium chloride in a highly purified hydrocarbon solvent to obtain a magnesium chloride slurry;
• ii) adding to the slurry at least one ether and stirring the mixture for a period of time to obtain a partially activated magnesium chloride;
• iii) filtering and washing the partially activated magnesium chloride slurry with a highly purified hydrocarbon solvent until no ether is detected in the washing liquid, to obtain a washed partially activated magnesium chloride;
• iv) adding thereto, in drop wise fashion, an alkyl aluminium compound followed by grinding to a smooth consistency and cooling to room temperature, to obtain an activated magnesium chloride;
• v) washing the activated magnesium chloride with a highly purified hydrocarbon solvent until no alkyl aluminium is detected in the washing liquid, to obtain a washed activated magnesium chloride, which constitutes the support of the catalyst;
• vi) adding a mixture of alcohols to the washed support, followed by stirring, to obtain an alcohol loaded support;
• vii) washing the alcohol loaded support with a highly purified hydrocarbon solvent, to obtain a washed alcohol loaded support;
• viii) adding titanium tetrachloride to the washed alcohol loaded support, and grinding it to a smooth consistency to obtain a titanium loaded catalyst;
• and
• ix) washing the titanium loaded catalyst with a highly purified hydrocarbon solvent until no titanium is detected in the washing liquid, to obtain the catalyst.

A process for producing a polymer which comprises reacting at least ethylene as a first component or monomer, with a branched alpha olefin as a second component or monomer, and with a different branched alpha olefin as a third component or monomer, in one or more reaction zones, while maintaining the reaction zone(s) at a pressure between atmospheric pressure and 5000 kg/cm21 and at a temperature between ambient and 300° C., in the presence of a particular catalyst, or a catalyst system comprising a particular catalyst and a cocatalyst, with the particular catalyst being that obtained by:

• i) suspending partially anhydrous magnesium chloride in a highly purified hydrocarbon solvent to obtain a magnesium chloride slurry;
• ii) adding to the slurry at least one ether and stirring the mixture for a period of time to obtain a partially activated magnesium chloride;
• iii) washing the partially activated magnesium chloride with a highly purified hydrocarbon solvent until no ether is detected in the washing liquid, to obtain a washed partially activated magnesium chloride;
• iv) adding thereto, in drop wise fashion, an alkyl aluminium compound under stirring, and cooling to room temperature, to obtain an activated magnesium chloride;
• v) washing the activated magnesium chloride with a highly purified hydrocarbon solvent until no alkyl aluminium is detected in the washing liquid, to obtain a washed activated magnesium chloride, which constitutes the support of the catalyst;
• vi) adding a mixture of alcohols to the washed support, followed by stirring, to obtain an alcohol loaded support;
• vii) washing the alcohol loaded support with a highly purified hydrocarbon solvent, to obtain a washed alcohol loaded support;
• viii) adding titanium tetrachloride to the washed alcohol loaded support, and grinding it to a smooth consistency to obtain a titanium loaded catalyst;
• and
• ix) washing the titanium loaded catalyst with a highly purified hydrocarbon solvent until no titanium is detected in the washing liquid, to obtain the catalyst.