US 9,868,799 B2Granted

Procatalyst for polymerization of olefins

AssigneesSaudi Basic Industries Corporation, Sabic Global Technologies B.V.

InventorsInaamul Haq Siddiqui, Khalid Abdullah Al-Bahily, Khalid Mohammed Al-Gahtani

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Abstract

The invention relates to a procatalyst for polymerization of olefins. The invention also relates to a process for preparing said procatalyst. Furthermore, the invention is directed to a catalyst system for polymerization of olefins comprising the said procatalyst, a co-catalyst and optionally an external electron donor; a process of preparing polyolefins by contacting an olefin with said catalyst system and to polyolefins obtained or obtainable by said process. The invention also relates to the use of said procatalyst in the polymerization of olefins.

Claims9

Dependent claims

A process for preparing a procatalyst for preparing a catalyst composition for olefin polymerization, said process comprising:

i) contacting a compound R4zMgX42-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, being a solid Mg(OR1)xX12-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 may be substituted or unsubstituted, may contain one or more heteroatoms;
X4 and X1 are each independently selected from the group 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;
x is in a range of larger than 0 and smaller than 2, being 0<x<2;
ii) optionally contacting the solid Mg(OR1)xX12-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 reaction 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;
w is smaller than v;
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 may be substituted or unsubstituted, may contain one or more heteroatoms;
iii) contacting the first or second intermediate reaction product obtained in step i) or ii) respectively, with a halogen-containing titanium compound and either an activator or an internal electron donor to obtain a third intermediate reaction product;
iv) modifying the third intermediate reaction product obtained in step iii) with a modifier having the formula M(p)Xp, wherein M is selected from the group consisting of aluminum, boron, gallium, zinc, copper, thallium, indium, vanadium, chromium and iron, p is the oxidation state of M, and wherein X is a halide, to yield a modified intermediate reaction product;
and
v) contacting said modified intermediate reaction product obtained in step iv) with a halogen-containing titanium compound and, in the case that in step iii) an activator was used, an internal donor to obtain the procatalyst.

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Dependencies are inferred from the claim text.

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Abstract

A process for preparing a procatalyst for preparing a catalyst composition for olefin polymerization, said process comprising:

i) contacting a compound R4zMgX42-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, being a solid Mg(OR1)xX12-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 may be substituted or unsubstituted, may contain one or more heteroatoms;
X4 and X1 are each independently selected from the group 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;
x is in a range of larger than 0 and smaller than 2, being 0<x<2;
ii) optionally contacting the solid Mg(OR1)xX12-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 reaction 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;
w is smaller than v;
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 may be substituted or unsubstituted, may contain one or more heteroatoms;
iii) contacting the first or second intermediate reaction product obtained in step i) or ii) respectively, with a halogen-containing titanium compound and either an activator or an internal electron donor to obtain a third intermediate reaction product;
iv) modifying the third intermediate reaction product obtained in step iii) with a modifier having the formula M(p)Xp, wherein M is selected from the group consisting of aluminum, boron, gallium, zinc, copper, thallium, indium, vanadium, chromium and iron, p is the oxidation state of M, and wherein X is a halide, to yield a modified intermediate reaction product;
and
v) contacting said modified intermediate reaction product obtained in step iv) with a halogen-containing titanium compound and, in the case that in step iii) an activator was used, an internal donor to obtain the procatalyst.

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