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US 9,944,724 B2Granted
Ziegler-Natta catalysts doped with non-group IV metal chlorides
AssigneeFina Technology, Inc.
InventorsLei Zhang, David Knoeppel
Life of this patent
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Abstract
A process may include contacting ethylene monomer with Ziegler-Natta catalyst to form polyethylene. The Ziegler-Natta catalyst may be formed by contacting an alkyl magnesium compound with an alcohol and a metal reagent to form a blend, and contacting the blend with a first agent to form a solution of reaction product “A”. The solution of reaction product “A” may be contacted with a second agent to form a solid reaction product “B”, and the solid reaction product “B” may be contacted with a third agent to form a solid reaction product “C”. The solid reaction product “C” may be contacted with a fourth agent to form a solid reaction product “D”, and the solid reaction product “D” may be contacted with a fifth agent to form a catalyst component.
Claims13
A polymerization process comprising:
- providing ethylene monomer;
- contacting the ethylene monomer with a Ziegler-Natta catalyst within a polymerization reactor under conditions sufficient to form polyethylene;
- and
- recovering polyethylene from the polymerization reactor, wherein the Ziegler-Natta catalyst is formed by a process comprising:
- contacting an alkyl magnesium compound with an alcohol and a metal reagent to form a blend of a magnesium dialkoxide compound and a metal;
- contacting the blend of the magnesium dialkoxide compound and the metal with a first agent to form a solution of reaction product “A”, the first agent comprising a halogenating/titanating agent;
- contacting the solution of reaction product “A” with a second agent to form a solid reaction product “B”, the second agent comprising a blend of a first metal halide and a metal alkoxide;
- contacting the solid reaction product “B” with a third agent to form a solid reaction product “C”, the third agent comprising a second metal halide;
- contacting the solid reaction product “C” with a fourth agent to form a solid reaction product “D”, the fourth agent comprising a third metal halide;
- and
- contacting the solid reaction product “D” with a fifth agent to form a catalyst component, the fifth agent comprising an organoaluminum compound;
- wherein the metal reagent is selected from Ba(2-EHO)2 (barium(II) 2-ethyl hexyl alkoxide), Mn(2-ethylhexanoate)2 (manganese(II) 2-ethylhexanoate), Cr(2-ethylhexanoate)3 (chromium(III) 2-ethylhexanoate) and 2-butylferrocene.
9 more elements
A polymerization process comprising:
- providing ethylene monomer;
- contacting the ethylene monomer with a Ziegler-Natta catalyst within a polymerization reactor under conditions sufficient to form polyethylene;
- and
- recovering polyethylene from the polymerization reactor, wherein the Ziegler-Natta catalyst is formed by a process comprising:
- contacting an alkyl magnesium compound with an alcohol and a metal reagent to form a blend of a magnesium dialkoxide compound and a metal;
- contacting the blend of the magnesium dialkoxide compound and the metal with a first agent to form a solution of reaction product “A”, the first agent comprising a halogenating/titanating agent;
- contacting the solution of reaction product “A” with a second agent to form a solid reaction product “B”, the second agent comprising a blend of a first metal halide and a metal alkoxide;
- contacting the solid reaction product “B” with a third agent to form a solid reaction product “C”, the third agent comprising a second metal halide;
- contacting the solid reaction product “C” with a fourth agent to form a solid reaction product “D”, the fourth agent comprising a third metal halide;
- and
- contacting the solid reaction product “D” with a fifth agent to form a catalyst component, the fifth agent comprising an organoaluminum compound;
- wherein the metal in the metal reagent is selected from Cr3+, Fe2+, Mn2+, and Ba2+.
9 more elements
A polymerization process comprising:
- providing ethylene monomer;
- contacting the ethylene monomer with a Ziegler-Natta catalyst within a polymerization reactor under conditions sufficient to form polyethylene;
- and
- recovering polyethylene from the polymerization reactor, wherein the Ziegler-Natta catalyst is formed by a process comprising:
- contacting a metal component with a magnesium dihalide support material to form a Ziegler-Natta catalyst precursor, wherein the metal component is represented by the formula:
- MRAx
- wherein M is a transition metal;
- wherein RA is a halogen, an alkoxy, or a hydrocarboxyl group;
- and wherein x is the valence of M;
- contacting the magnesium dihalide support material in the Ziegler-Natta catalyst precursor with a dopant comprising a non-Group IV metal to form a doped catalyst precursor;
- and
- activating the doped catalyst precursor by contact with an organoaluminum compound to form the Ziegler-Natta catalyst;
- wherein the dopant is selected from Ba(2-EHO)2 (barium(II) 2-ethyl hexyl alkoxide), Mn(2-ethylhexanoate)2 (manganese(II) 2-ethylhexanoate), Cr(2-ethylhexanoate)3 (chromium(III) 2-ethylhexanoate), 2-butylferrocene and combinations thereof.
10 more elements
Dependencies are inferred from the claim text.