CA2107634C - Titanium catalyst component for ethylene polymerization, ethylene polymerization catalyst, and process for ethylene polymerization using the same - Google Patents
Titanium catalyst component for ethylene polymerization, ethylene polymerization catalyst, and process for ethylene polymerization using the sameInfo
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- CA2107634C CA2107634C CA002107634A CA2107634A CA2107634C CA 2107634 C CA2107634 C CA 2107634C CA 002107634 A CA002107634 A CA 002107634A CA 2107634 A CA2107634 A CA 2107634A CA 2107634 C CA2107634 C CA 2107634C
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- titanium
- magnesium
- catalyst component
- alcohol
- compound
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
- C08F10/02—Ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F4/00—Polymerisation catalysts
- C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
- C08F4/62—Refractory metals or compounds thereof
- C08F4/64—Titanium, zirconium, hafnium or compounds thereof
- C08F4/642—Component covered by group C08F4/64 with an organo-aluminium compound
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F4/00—Polymerisation catalysts
- C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
- C08F4/62—Refractory metals or compounds thereof
- C08F4/64—Titanium, zirconium, hafnium or compounds thereof
- C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
- C08F4/652—Pretreating with metals or metal-containing compounds
- C08F4/658—Pretreating with metals or metal-containing compounds with metals or metal-containing compounds, not provided for in a single group of groups C08F4/653 - C08F4/657
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
- C08F110/02—Ethene
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
- Y10S526/904—Monomer polymerized in presence of transition metal containing catalyst at least part of which is supported on a polymer, e.g. prepolymerized catalysts
Abstract
Disclosed is a titanium catalyst component for ethylene polymerization obtained by contacting [A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, with [B] a tetravalent titanium compound.
The solid magnesium aluminum complex [A] is obtained by contacting (a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound. Also disclosed is a process for ethylene polymerization comprising polymerizing ethylene or copolymerizing ethylene with an .alpha.-olefin having 3 to 20 carbon atoms in the presence of a catalyst for ethylene polymerization comprising [I] the above-mentioned titanium catalyst component for ethylene polymerization and [II] an organoaluminum compound catalyst component.
The solid magnesium aluminum complex [A] is obtained by contacting (a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound. Also disclosed is a process for ethylene polymerization comprising polymerizing ethylene or copolymerizing ethylene with an .alpha.-olefin having 3 to 20 carbon atoms in the presence of a catalyst for ethylene polymerization comprising [I] the above-mentioned titanium catalyst component for ethylene polymerization and [II] an organoaluminum compound catalyst component.
Description
TITLE
TITANIUM CATALYST COMPONENT FOR ETHYLENE POLYMERIZATION, ETHYLENE POLYMERIZATION CATALYST, AND PROCESS FOR ETHYLENE
FIELD OF THE INVENTION
The present invention relates to a titanium catalyst component for ethylene polymerization by the use of which an ethylene polymer having a narrow particle size distribution can be prepared with a high polymerization activity, to an ethylene polymerization catalyst comprising the titanium catalyst component, and to a process for ethylene polymerization using this ethylene polymerization catalyst.
BACKGROUND OF THE INVENTION
For preparing ethylene polymers, generally known in the art is a process of copolymerizing ethylene with an ~-olefin or polymerizing ethylene in the presence of aZiegler catalyst. In this process, a high-temperature solution polymerization wherein polymerization is conducted in a hydrocarbon solvent at a temperature higher than the melting point of the resultant polymer is broadly utilized.
However, if a polymer having a high molecular weight is intended to be obtained, a polymer concentration in the polymer solution must be lowered because the viscosity of the polymer solution becomes high with increase of the molecular weight. As a result, a problem of low productivity of a polymer takes place.
On the other hand, in the case of conducting the polymerization by a slurry polymerization process, there 5 resides other problem. That is, the resultant polymer swells easily in a polymerization solvent. As a result, the concentration of the slurry can be hardly helghtened and a long-term continuous polymerization operation can be difficultly made.
The present inventors have studied in the light of the problems associated with the prior art as mentioned above, and proposed a titanium catalyst component for ethylene polymerization as described in, for example, Japanese Patent Laid-Open Publication No. 195108/1985. This titanium catalyst component is excellent in handling property as a slurry and makes it possible to conduct polymerization operation in a high concentration of the slurry. In the titanium catalyst, more than 70% by weight of titanium atoms are reduced to trivalent state. By the use of this titanium catalyst component, an ethylene polymer having an excellent composition (copolymer) distribution can be prepared with a high polymerization activity.
As described above, by the use of the catalyst component for ethylene polymerization disclosed in Japanese Patent Laid-Open Publication No. 195108/1985, ethylene can be polymerized with a high polymerization activity, and 210~63~
moreover, an ethylene copolymer having a narrow composition dlstribution and excellent morphology can be obtained.
However, now eagerly desired is a titanium catalyst component for ethylene polymerization by the use of which 5 an ethylene polymer can be prepared with a high polymerization activity.
Further, Japanese Patent Publication No. 45404/1988 discloses a process for the preparation of a solid titanium catalyst component. In this process, the solid titanium catalyst component is prepared by contacting a magnesium aluminum complex which is obtained by the contact of an alcohol solution of halogen-containing magnesium with an organoaluminum compound, an electron donor having no active hydrogen and titanium tetrachloride to react with each other. The solid titanium catalyst component obtained in this process has a good particle size distribution, and hence polyolefin obtained by using a catalyst comprising this solid titanium catalyst component also has a good particle size distribution. However, the advent of a solid titanium catalyst component which has excellent catalytic activity for ethylene polymerization has been eagerly desired.
Furthermore, Japanese Patent Laid-Open Publication No.
159806/1982 discloses:
a solid titanium catalyst component prepared by bringing a product obtained by reacting a reaction product (a1) of halogen-containing magnesium and an alcohol with an organoaluminum compound into contact with a halogen-containing titanium compound, said solid titanium catalyst component having a molar ratio of alkoxy group and/or alcohol to titanium of not more than 0.25;
a solid titanium catalyst component prepared by bringing a product obtained by reacting a reaction product (a1) of halogen-containing magnesium and an alcohol with an organoaluminum compound into contact with a halogen-containing titanium compound and subsequently bringing the resulting product into contact with an organoaluminum halide (halogenation agent), said solid titanium catalyst component having a molar ratio of alkoxy group and/or alcohol to titanium of not more than 0.9; and a solid titanium catalyst component obtained by bringing a product prepared by reacting a reaction product (a1) of halogen-containing magnesium and an alcohol with an organoaluminum compound into contact with an organoaluminum halide (halogenation agent), subsequently bringing the resulting product into contact with a halogen-containing titanium compound and further bringing the resulting product into contact with an organoaluminum halide (halogenation agent), said solid titanium catalyst component having a molar ratio of alkoxy group and/or alcohol to titanium of not more than 0.9.
In such solid titanium catalyst components, a molar ratio Ti3+/Ti4+ is in the range of 2.0 to 10, and most of the tetravalent titanium atoms are reduced into trivalent s state. By the use of these catalyst components, ethylene can be polymerized with a high polymerization activity.
However, further desired is the advent of a solid titanium catalyst component for ethylene polymerization which has a 5 narrower particle size distribution and by the use of which ethylene can be polymerized with much higher polymerization activity.
Moreover, Japanese Patent Laid-Open Publication No.
91106/1992 discloses a solid titanium catalyst component obtained by contacting with each other:
a solid magnesium aluminum complex obtained by contacting a solution formed from halogen-containing magnesium, an alcohol and a hydrocarbon solvent with organoaluminum, a tetravalent compound in a liquid state, and a vanadium compound, a zirconium compound or a hafnium compound.
- In the comparative example of the above Japanese Patent Laid-Open Publication No. 91106/1992, an experiment wherein 2-ethylhexoxytitanium trichloride was used as the tetravalent titanium compound and no vanadium compound was used is shown.
In such solid titanium catalyst component as obtained above, most of titanium atoms are reduced into trivalent state, and the catalyst component is low in the activity for ethylene polymerization. Accordingly, a solid titanium 210763~
catalyst component having a much higher activity for ethylene polymerization is now desired.
OBJECT OF THE INVENTION
It is, therefore, an object of the present invention to provide a titanium catalyst component for ethylene polymerization by the use of which an ethylene polymer having a narrow particle size distribution can be prepared with a high polymerization activity, to provide an ethylene polymerization catalyst comprising the titanium catalyst component and to provide a process for polymerizing ethylene using this titanium catalyst component.
SUMMARY OF THE INVENTION
The titanium catalyst component for ethylene polymerization according to the present invention is a titanium catalyst component for ethylene polymerization prepared by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, said complex being obtained by contacting (a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound; with [B] a tetravalent titanium compound, wherein titanium atoms contained in the titanium catalyst component are substantially tetravalent and a molar ratio of alkoxy group and/or alcohol to titanium (OR/Ti) is in the range of 0.26 to 6Ø
This titanium catalyst component for ethylene polymerization contains, as essential components, magnesium, halogen, aluminum, an alkoxy group and/or alcohol having at least 6 carbon atoms and titanium.
A prepolymerized titanium catalyst component [I]' for ethylene polymerization according to the present invention is obtained by prepolymerizing an olefin to the titanium catalyst component [I] as mentioned above.
The first ethylene polymerization catalyst according to the present invention comprises the tltanium catalyst component [I] and an organoaluminum compound [II].
The second ethylene polymerization catalyst according to the present invention comprises the prepolymerized titanium catalyst component[I]' and an organoaluminum compound [II].
The process for ethylene polymerization according to the present invention comprises polymerizing ethylene or copolymerizing ethylene with an a-olefin having 3 to 20 carbon atoms in the presence of the ethylene polymerization catalyst.
BRIEF DESCRIPTION OF THE DRAWING
210763~
Fig. 1 shows steps of a process for preparing the titanium catalyst component for ethylene polymerization according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The titanium catalyst component for ethylene polymerization according to the present invention, a catalyst for ethylene polymerization containing the titanium catalyst component and a process for (co)polymerizing ethylene using the titanium catalyst component will be described in detail hereinafter.
The meaning of the term "polymerization" used herein is not limited to "homopolymerization" but may comprehend "copolymerization". Also, the meaning of the term "polymer" used herein is not limited to "homopolymer" but may comprehend "copolymer".
Fig. 1 is an explanatory view showing one example of a process for preparing the titanium catalyst component for ethylene polymerization according to the present invention.
The titanium catalyst component for ethylene polymerization according to the present invention is obtained by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, said complex being obtained by contacting (a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound; with [B] a tetravalent titanium compound.
First, the solid magnesium aluminum complex [A]
containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms is described below.
The solid magnesium aluminum complex [A] is obtained by contacting:
(a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound.
In the solid magnesium aluminum complex [A], the atomic ratio Al/Mg (Al: aluminum, Mg: magnesium) is in the range of usually 0.05 to 1, preferably 0.08 to 0,7, more preferably 0.12 to 0.6. The alkoxy group and/or alcohol having at least 6 carbon atoms is contained, based on 1 part by weight of magnesium, in an amount of usually 0.5 to 15 parts by weight, preferably 2 to 13 parts by weight, more preferably 5 to lO parts by weight. The atomic ratio X1/Mg (X1: halogen) is in the range of usually 1 to 3, preferably 1.5 to 2.5.
The solid magnesium aluminum complex [A] is desired to be particulate, and the diameters of the solid magnesium 1 o aluminum complex particles are preferably in the range of 1 to 200 ~m, more preferably 2 to 100 ~m. With respect to the particle size distribution of the complex [A], the geometrical standard deviation is preferably in the range of 1.0 to 2.0, particularly preferably 1.0 to 1.8.
Concrete examples of the halogen-containing magnesium compound for use in the preparation of the magnesium solution (a-1) in the invention include:
magnesium halides, such as magnesium chloride, magnesium bromide, magnesium iodide and magnesium fluoride;
alkoxymagnesium halides, such as methoxymagnesium chloride, ethoxymagnesium chloride, isopropoxymagnesium chloride, butoxymagnesium chloride and octoxymagnesium chloride;
aryloxymagnesium halides, such as phenoxymagnesium chloride and methylphenoxymagnesium chloride;
alkoxymagnesiums, such as diethoxymagnesium, diisopropoxymagnesium, dibutoxymagnesium, and dioctoxymagnesium;
aryloxymagnesiums, such as diphenoxymagnesium and dimethylphenoxymagnesium; and magnesium carboxylates, such as magnesium laurate and magnesium stearate.
These compounds may be used as a complex or double compound with another metal, or may be used as a mixture with another metallic compound.
~ ~7~3 4 Of these, preferred are magneslum halldes and alkoxymagneslum halldes; more preferred are magneslum chlorlde and alkoxy magneslum chlorldei and most preferred ls magneslum chlorlde.
These compounds may be used slngly or ln comblnatlon.
The magnesium compound solutlon (a-l), that ls used ln a llquld state ln the lnventlon, ls formed from the halogen-contalnlng magneslum compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent.
Specific examples of the alcohol havlng at least 6 carbon atoms for use ln the lnventlon include:
allphatlc alcohols, such as 2-methylpentanol, 2-ethylpentanol, 2-etl1ylbutanol, n-heptanol, n-octanol, 2-ethylhexanol, decanol, dodecanol, tetradecyl alcohol, undecenol, oleyl alcohol and stearyl alcoholi allcycllc alcohols, such as cyclohexanol and methylcyclohexanol;
aromatlc alcohols, such as benzyl alcohol, methylbenzyl alcohol, lsopropylbenzyl alcohol, ~-methylbenzyl alcohol and ~,~-dlme~ylbenzyl alcohol; and alkoxy group-containlng allphatic alcohols, such as n-butyl cellosolve and l-butoxy-2-propanol.
Preferred are alcohols havlng 7 to 1~ carbon ato~s.
Of these, 2-ethylhexanol ls partlcularly preferred.
These alcohol~ may be used singly or ln comblnation.
Wl1en the halogen-contalning magneslum compound, the alcohol having at least 6 carbon atoms and a hydrocarbon 2107~3~
solvent are brought into contact with each other, the halogen-containing magnesium compound is dissolved in the hydrocarbon solvent to give a magnesium solution.
Concrete examples of the hydrocarbon solvent include:
aliphatic hydrocarbons, such as propane, butane, n-pentane, isopentane, n-hexane, isohexane, n-heptane, n-octane, isooctane, n-decane, n-dodecane and kerosine;
alicyclic hydrocarbons, such as cyclopentane, methylcyclopentane, cyclohexane and methylcyclohexane;
aromatic hydrocarbons, such as benzene, toluene and xylene; and halogenated hydrocarbons, such as methylene dichloride, ethyl chloride, ethylene dichloride and chlorobenzene.
Of these, aliphatic hydrocarbons, particularly those of 3 to 10 carbon atoms, are preferably employed.
These hydrocarbon solvents may be used singly or in combination.
The contact of the halogen-containing magnesium compound, the alcohol having at least 6 carbon atoms and the hydrocarbon solvent with each other is carried out at a temperature of usually not lower than room temperature, preferably not lower than 65 ~C, more preferably about 80 to 300 ~C, most preferably about 100 to about 200 ~C, for a period of 15 minutes to 5 hours, preferably 30 minutes to 3 hours, though these conditions vary depending upon the compound and the alcohol used, etc.
2107~4 The alcohol is used in an amount of generally not less than 1 mol, preferably about 1.5 to about 20 mol, more preferably about 2.0 to about 12 mole, per 1 mol of the halogen-containing magnesium compound, though this amount varies depending upon the magnesium compound and the solvent used, etc.
By contacting the magnesium solution (a-1) with an organoaluminum compound (a-2), a solid magnesium aluminum complex [A] is obtained.
Preferably used as the organoaluminum compound (a-2) in the invention is, for example, an organoaluminum compound represented by the following formula (iv):
RanAlx3-n ( iv) wherein Ra is a hydrocarbon group of l to 12 carbon atoms, X is a halogen atom or hydrogen, and n is 1 to 3.
The hydrocarbon group of 1 to 12 carbon atoms includes an alkyl group, a cycloalkyl group and an aryl group.
Examples of such groups include methyl, ethyl, n-propyl, isopropyl, isobutyl, pentyl, hexyl, octyl, cyclopentyl, cyclohexyl, phenyl and tolyl.
Concrete examples of such organoaluminum compound (a-2) include:
trialkylaluminums, such as trimethylaluminum, triethylaluminum, triisopropylaluminum, triisobutylaluminum, trioctylaluminum and tri-2-ethylhexylaluminum;
alkenylaluminums, such as isoprenylaluminum;
2107~34 dialkylaluminum halides such as dimethylaluminum chloride, diethylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride and dimethylaluminum bromide;
alkylaluminum sesquihalides, such as methylaluminum sesquichloride, ethylaluminum sesquichloride, isopropylaluminum sesquichloride, butylaluminum sesquichloride and ethylaluminum sesquibromide;
alkylaluminum dihalides, such as methylaluminum dichloride, ethylaluminum dichloride, isopropylaluminum dichloride and ethylaluminum dibromide; and alkylaluminum hydrides, such as diethylaluminum hydride and diisobutylaluminum hydride.
Also employable as the organoaluminum compound is a compound represented by the following formula (v):
RanAl Y 3 -n ( v ) wherein Ra is the same as Ra in the above formula (iv); n is 1 or 2; and Y is -ORb, -OSiRC3, -OAlRd2, -NRe2, -SiRf3 or -N(Rg)AlRh2 (wherein Rb, RC, Rd and Rh are each methyl, ethyl, isopropyl, isobutyl, cyclohexyl or phenyl; Re is hydrogen, methyl, ethyl, isopropyl, phenyl or trimethylsilyl; and Rf and Rg are each methyl or ethyl).
Concrete examples of such organoaluminum compounds include:
(1) compounds of the formula RanAl(ORb)3-nl such as dimethylaluminum methoxide, diethylaluminum ethoxide and diisobutylaluminum methoxide;
210763~
(2) compounds of the formula RanAl(OSiRC3)3-n~ such as Et2Al~OSiMe3), (iso-Bu)2Al(OSiMe3) and (iso-Bu)2Al(OSiEt3);
TITANIUM CATALYST COMPONENT FOR ETHYLENE POLYMERIZATION, ETHYLENE POLYMERIZATION CATALYST, AND PROCESS FOR ETHYLENE
FIELD OF THE INVENTION
The present invention relates to a titanium catalyst component for ethylene polymerization by the use of which an ethylene polymer having a narrow particle size distribution can be prepared with a high polymerization activity, to an ethylene polymerization catalyst comprising the titanium catalyst component, and to a process for ethylene polymerization using this ethylene polymerization catalyst.
BACKGROUND OF THE INVENTION
For preparing ethylene polymers, generally known in the art is a process of copolymerizing ethylene with an ~-olefin or polymerizing ethylene in the presence of aZiegler catalyst. In this process, a high-temperature solution polymerization wherein polymerization is conducted in a hydrocarbon solvent at a temperature higher than the melting point of the resultant polymer is broadly utilized.
However, if a polymer having a high molecular weight is intended to be obtained, a polymer concentration in the polymer solution must be lowered because the viscosity of the polymer solution becomes high with increase of the molecular weight. As a result, a problem of low productivity of a polymer takes place.
On the other hand, in the case of conducting the polymerization by a slurry polymerization process, there 5 resides other problem. That is, the resultant polymer swells easily in a polymerization solvent. As a result, the concentration of the slurry can be hardly helghtened and a long-term continuous polymerization operation can be difficultly made.
The present inventors have studied in the light of the problems associated with the prior art as mentioned above, and proposed a titanium catalyst component for ethylene polymerization as described in, for example, Japanese Patent Laid-Open Publication No. 195108/1985. This titanium catalyst component is excellent in handling property as a slurry and makes it possible to conduct polymerization operation in a high concentration of the slurry. In the titanium catalyst, more than 70% by weight of titanium atoms are reduced to trivalent state. By the use of this titanium catalyst component, an ethylene polymer having an excellent composition (copolymer) distribution can be prepared with a high polymerization activity.
As described above, by the use of the catalyst component for ethylene polymerization disclosed in Japanese Patent Laid-Open Publication No. 195108/1985, ethylene can be polymerized with a high polymerization activity, and 210~63~
moreover, an ethylene copolymer having a narrow composition dlstribution and excellent morphology can be obtained.
However, now eagerly desired is a titanium catalyst component for ethylene polymerization by the use of which 5 an ethylene polymer can be prepared with a high polymerization activity.
Further, Japanese Patent Publication No. 45404/1988 discloses a process for the preparation of a solid titanium catalyst component. In this process, the solid titanium catalyst component is prepared by contacting a magnesium aluminum complex which is obtained by the contact of an alcohol solution of halogen-containing magnesium with an organoaluminum compound, an electron donor having no active hydrogen and titanium tetrachloride to react with each other. The solid titanium catalyst component obtained in this process has a good particle size distribution, and hence polyolefin obtained by using a catalyst comprising this solid titanium catalyst component also has a good particle size distribution. However, the advent of a solid titanium catalyst component which has excellent catalytic activity for ethylene polymerization has been eagerly desired.
Furthermore, Japanese Patent Laid-Open Publication No.
159806/1982 discloses:
a solid titanium catalyst component prepared by bringing a product obtained by reacting a reaction product (a1) of halogen-containing magnesium and an alcohol with an organoaluminum compound into contact with a halogen-containing titanium compound, said solid titanium catalyst component having a molar ratio of alkoxy group and/or alcohol to titanium of not more than 0.25;
a solid titanium catalyst component prepared by bringing a product obtained by reacting a reaction product (a1) of halogen-containing magnesium and an alcohol with an organoaluminum compound into contact with a halogen-containing titanium compound and subsequently bringing the resulting product into contact with an organoaluminum halide (halogenation agent), said solid titanium catalyst component having a molar ratio of alkoxy group and/or alcohol to titanium of not more than 0.9; and a solid titanium catalyst component obtained by bringing a product prepared by reacting a reaction product (a1) of halogen-containing magnesium and an alcohol with an organoaluminum compound into contact with an organoaluminum halide (halogenation agent), subsequently bringing the resulting product into contact with a halogen-containing titanium compound and further bringing the resulting product into contact with an organoaluminum halide (halogenation agent), said solid titanium catalyst component having a molar ratio of alkoxy group and/or alcohol to titanium of not more than 0.9.
In such solid titanium catalyst components, a molar ratio Ti3+/Ti4+ is in the range of 2.0 to 10, and most of the tetravalent titanium atoms are reduced into trivalent s state. By the use of these catalyst components, ethylene can be polymerized with a high polymerization activity.
However, further desired is the advent of a solid titanium catalyst component for ethylene polymerization which has a 5 narrower particle size distribution and by the use of which ethylene can be polymerized with much higher polymerization activity.
Moreover, Japanese Patent Laid-Open Publication No.
91106/1992 discloses a solid titanium catalyst component obtained by contacting with each other:
a solid magnesium aluminum complex obtained by contacting a solution formed from halogen-containing magnesium, an alcohol and a hydrocarbon solvent with organoaluminum, a tetravalent compound in a liquid state, and a vanadium compound, a zirconium compound or a hafnium compound.
- In the comparative example of the above Japanese Patent Laid-Open Publication No. 91106/1992, an experiment wherein 2-ethylhexoxytitanium trichloride was used as the tetravalent titanium compound and no vanadium compound was used is shown.
In such solid titanium catalyst component as obtained above, most of titanium atoms are reduced into trivalent state, and the catalyst component is low in the activity for ethylene polymerization. Accordingly, a solid titanium 210763~
catalyst component having a much higher activity for ethylene polymerization is now desired.
OBJECT OF THE INVENTION
It is, therefore, an object of the present invention to provide a titanium catalyst component for ethylene polymerization by the use of which an ethylene polymer having a narrow particle size distribution can be prepared with a high polymerization activity, to provide an ethylene polymerization catalyst comprising the titanium catalyst component and to provide a process for polymerizing ethylene using this titanium catalyst component.
SUMMARY OF THE INVENTION
The titanium catalyst component for ethylene polymerization according to the present invention is a titanium catalyst component for ethylene polymerization prepared by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, said complex being obtained by contacting (a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound; with [B] a tetravalent titanium compound, wherein titanium atoms contained in the titanium catalyst component are substantially tetravalent and a molar ratio of alkoxy group and/or alcohol to titanium (OR/Ti) is in the range of 0.26 to 6Ø
This titanium catalyst component for ethylene polymerization contains, as essential components, magnesium, halogen, aluminum, an alkoxy group and/or alcohol having at least 6 carbon atoms and titanium.
A prepolymerized titanium catalyst component [I]' for ethylene polymerization according to the present invention is obtained by prepolymerizing an olefin to the titanium catalyst component [I] as mentioned above.
The first ethylene polymerization catalyst according to the present invention comprises the tltanium catalyst component [I] and an organoaluminum compound [II].
The second ethylene polymerization catalyst according to the present invention comprises the prepolymerized titanium catalyst component[I]' and an organoaluminum compound [II].
The process for ethylene polymerization according to the present invention comprises polymerizing ethylene or copolymerizing ethylene with an a-olefin having 3 to 20 carbon atoms in the presence of the ethylene polymerization catalyst.
BRIEF DESCRIPTION OF THE DRAWING
210763~
Fig. 1 shows steps of a process for preparing the titanium catalyst component for ethylene polymerization according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The titanium catalyst component for ethylene polymerization according to the present invention, a catalyst for ethylene polymerization containing the titanium catalyst component and a process for (co)polymerizing ethylene using the titanium catalyst component will be described in detail hereinafter.
The meaning of the term "polymerization" used herein is not limited to "homopolymerization" but may comprehend "copolymerization". Also, the meaning of the term "polymer" used herein is not limited to "homopolymer" but may comprehend "copolymer".
Fig. 1 is an explanatory view showing one example of a process for preparing the titanium catalyst component for ethylene polymerization according to the present invention.
The titanium catalyst component for ethylene polymerization according to the present invention is obtained by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, said complex being obtained by contacting (a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound; with [B] a tetravalent titanium compound.
First, the solid magnesium aluminum complex [A]
containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms is described below.
The solid magnesium aluminum complex [A] is obtained by contacting:
(a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound.
In the solid magnesium aluminum complex [A], the atomic ratio Al/Mg (Al: aluminum, Mg: magnesium) is in the range of usually 0.05 to 1, preferably 0.08 to 0,7, more preferably 0.12 to 0.6. The alkoxy group and/or alcohol having at least 6 carbon atoms is contained, based on 1 part by weight of magnesium, in an amount of usually 0.5 to 15 parts by weight, preferably 2 to 13 parts by weight, more preferably 5 to lO parts by weight. The atomic ratio X1/Mg (X1: halogen) is in the range of usually 1 to 3, preferably 1.5 to 2.5.
The solid magnesium aluminum complex [A] is desired to be particulate, and the diameters of the solid magnesium 1 o aluminum complex particles are preferably in the range of 1 to 200 ~m, more preferably 2 to 100 ~m. With respect to the particle size distribution of the complex [A], the geometrical standard deviation is preferably in the range of 1.0 to 2.0, particularly preferably 1.0 to 1.8.
Concrete examples of the halogen-containing magnesium compound for use in the preparation of the magnesium solution (a-1) in the invention include:
magnesium halides, such as magnesium chloride, magnesium bromide, magnesium iodide and magnesium fluoride;
alkoxymagnesium halides, such as methoxymagnesium chloride, ethoxymagnesium chloride, isopropoxymagnesium chloride, butoxymagnesium chloride and octoxymagnesium chloride;
aryloxymagnesium halides, such as phenoxymagnesium chloride and methylphenoxymagnesium chloride;
alkoxymagnesiums, such as diethoxymagnesium, diisopropoxymagnesium, dibutoxymagnesium, and dioctoxymagnesium;
aryloxymagnesiums, such as diphenoxymagnesium and dimethylphenoxymagnesium; and magnesium carboxylates, such as magnesium laurate and magnesium stearate.
These compounds may be used as a complex or double compound with another metal, or may be used as a mixture with another metallic compound.
~ ~7~3 4 Of these, preferred are magneslum halldes and alkoxymagneslum halldes; more preferred are magneslum chlorlde and alkoxy magneslum chlorldei and most preferred ls magneslum chlorlde.
These compounds may be used slngly or ln comblnatlon.
The magnesium compound solutlon (a-l), that ls used ln a llquld state ln the lnventlon, ls formed from the halogen-contalnlng magneslum compound, an alcohol having at least 6 carbon atoms and a hydrocarbon solvent.
Specific examples of the alcohol havlng at least 6 carbon atoms for use ln the lnventlon include:
allphatlc alcohols, such as 2-methylpentanol, 2-ethylpentanol, 2-etl1ylbutanol, n-heptanol, n-octanol, 2-ethylhexanol, decanol, dodecanol, tetradecyl alcohol, undecenol, oleyl alcohol and stearyl alcoholi allcycllc alcohols, such as cyclohexanol and methylcyclohexanol;
aromatlc alcohols, such as benzyl alcohol, methylbenzyl alcohol, lsopropylbenzyl alcohol, ~-methylbenzyl alcohol and ~,~-dlme~ylbenzyl alcohol; and alkoxy group-containlng allphatic alcohols, such as n-butyl cellosolve and l-butoxy-2-propanol.
Preferred are alcohols havlng 7 to 1~ carbon ato~s.
Of these, 2-ethylhexanol ls partlcularly preferred.
These alcohol~ may be used singly or ln comblnation.
Wl1en the halogen-contalning magneslum compound, the alcohol having at least 6 carbon atoms and a hydrocarbon 2107~3~
solvent are brought into contact with each other, the halogen-containing magnesium compound is dissolved in the hydrocarbon solvent to give a magnesium solution.
Concrete examples of the hydrocarbon solvent include:
aliphatic hydrocarbons, such as propane, butane, n-pentane, isopentane, n-hexane, isohexane, n-heptane, n-octane, isooctane, n-decane, n-dodecane and kerosine;
alicyclic hydrocarbons, such as cyclopentane, methylcyclopentane, cyclohexane and methylcyclohexane;
aromatic hydrocarbons, such as benzene, toluene and xylene; and halogenated hydrocarbons, such as methylene dichloride, ethyl chloride, ethylene dichloride and chlorobenzene.
Of these, aliphatic hydrocarbons, particularly those of 3 to 10 carbon atoms, are preferably employed.
These hydrocarbon solvents may be used singly or in combination.
The contact of the halogen-containing magnesium compound, the alcohol having at least 6 carbon atoms and the hydrocarbon solvent with each other is carried out at a temperature of usually not lower than room temperature, preferably not lower than 65 ~C, more preferably about 80 to 300 ~C, most preferably about 100 to about 200 ~C, for a period of 15 minutes to 5 hours, preferably 30 minutes to 3 hours, though these conditions vary depending upon the compound and the alcohol used, etc.
2107~4 The alcohol is used in an amount of generally not less than 1 mol, preferably about 1.5 to about 20 mol, more preferably about 2.0 to about 12 mole, per 1 mol of the halogen-containing magnesium compound, though this amount varies depending upon the magnesium compound and the solvent used, etc.
By contacting the magnesium solution (a-1) with an organoaluminum compound (a-2), a solid magnesium aluminum complex [A] is obtained.
Preferably used as the organoaluminum compound (a-2) in the invention is, for example, an organoaluminum compound represented by the following formula (iv):
RanAlx3-n ( iv) wherein Ra is a hydrocarbon group of l to 12 carbon atoms, X is a halogen atom or hydrogen, and n is 1 to 3.
The hydrocarbon group of 1 to 12 carbon atoms includes an alkyl group, a cycloalkyl group and an aryl group.
Examples of such groups include methyl, ethyl, n-propyl, isopropyl, isobutyl, pentyl, hexyl, octyl, cyclopentyl, cyclohexyl, phenyl and tolyl.
Concrete examples of such organoaluminum compound (a-2) include:
trialkylaluminums, such as trimethylaluminum, triethylaluminum, triisopropylaluminum, triisobutylaluminum, trioctylaluminum and tri-2-ethylhexylaluminum;
alkenylaluminums, such as isoprenylaluminum;
2107~34 dialkylaluminum halides such as dimethylaluminum chloride, diethylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride and dimethylaluminum bromide;
alkylaluminum sesquihalides, such as methylaluminum sesquichloride, ethylaluminum sesquichloride, isopropylaluminum sesquichloride, butylaluminum sesquichloride and ethylaluminum sesquibromide;
alkylaluminum dihalides, such as methylaluminum dichloride, ethylaluminum dichloride, isopropylaluminum dichloride and ethylaluminum dibromide; and alkylaluminum hydrides, such as diethylaluminum hydride and diisobutylaluminum hydride.
Also employable as the organoaluminum compound is a compound represented by the following formula (v):
RanAl Y 3 -n ( v ) wherein Ra is the same as Ra in the above formula (iv); n is 1 or 2; and Y is -ORb, -OSiRC3, -OAlRd2, -NRe2, -SiRf3 or -N(Rg)AlRh2 (wherein Rb, RC, Rd and Rh are each methyl, ethyl, isopropyl, isobutyl, cyclohexyl or phenyl; Re is hydrogen, methyl, ethyl, isopropyl, phenyl or trimethylsilyl; and Rf and Rg are each methyl or ethyl).
Concrete examples of such organoaluminum compounds include:
(1) compounds of the formula RanAl(ORb)3-nl such as dimethylaluminum methoxide, diethylaluminum ethoxide and diisobutylaluminum methoxide;
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(2) compounds of the formula RanAl(OSiRC3)3-n~ such as Et2Al~OSiMe3), (iso-Bu)2Al(OSiMe3) and (iso-Bu)2Al(OSiEt3);
(3) compounds of the formula RanAl(OAlRd2)3-n, such as Et2AlOAlEt2 and (iso-Bu)2AlOAl(iso-Bu)2;
(9) compounds of the formula RanAl(NRe2)3-n, such as Me2AlNEt2, Et2AlNHMe, Me2AlNHEt, Et2AlN(Me3Si)2 and (iso-Bu)2AlN(Me3si)2;
(5) compounds of the formula RanAl(SiRf3)3-n, such as (iso-Bu)2AlSiMe3; and (6) compounds of the formula RanAl[N(Rg)AlRh2]3-n, such as Et2AlN(Me)AlEt2 and (iso-Bu)2AlN(Et)Al(iso-Bu)2.
In addition, also employable as the the organoaluminum compound (a-2) is a complex alkylate which is formed from a metal of Group I of the periodic table and aluminum, said complex alkylate being represented by the following formula:
MlAlR i 4 wherein M1 is Li, Na or K, and Rj is a hydrocarbon group of 1 to 15 carbon atoms.
Concrete examples of such complex alkylate include LiAl(C2H5)4 and LiAl(C7H1s)4.
Of the organoaluminum compounds as exemplified above, preferably used are trialkylaluminum, dialkylaluminum halide, dialkylaluminum hydride and dialkylaluminum alkoxide. Of these, trialkylaluminum, particularly triethylaluminum, is preferred because a catalyst with a favorable shape can be obtained by using it.
2i~763~
l6 These organoaluminum compounds may be used alone or in combination.
For forming the solid magnesium aluminum complex [A], the organoaluminum compound (a-2) is desirably used in such S an amount that the molar ratio (ROH/Al) of the alcohol (ROH) having at least 6 carbon atoms used for the preparation of the magnesium solution (a-l) to the aluminum atom (Al) contained in the organoaluminum compound (a-2) is in the range of about 0.5 to 7, preferably 1 to 5.
The contact of the magnesium solution (a-l) with the organoaluminum compound (a-2) can be carried out by dropwise adding the organoaluminum compound (a-2) slowly to the magnesium solution (a-l) having a magnesium concentration of preferably 0.005 to 2 mol/l, more preferably 0.05 to 1 mol/l, with stirring of the magnesium solution. In this manner, a solid magnesium aluminum complex [A] having excellent particle properties (excellent morphology) can be obtained.
The temperature for contacting the magnesium solution (a-l) with the organoaluminum compound (a-2) is in the range of usually -50 to 150 ~C, preferably -30 to 100 ~C.
The solid magnesium aluminum complex [A] thus obtained contains no reducing organic group, and hence it exhibits no reduction ability.
The titanium catalyst component for ethylene polymerization [I] according to the present invention is obtained by contactlng the above-described solid magnesium aluml1)u1n complex ~A; wl~h a tetravalent cornpound l~.
Preferably used as the tetravalent titanium compound [Bl is a compound represented by the follow~ng formula (ll):
Tl(OR2)9X4_9 (ll) wherein ~ is a hydrocarbon group, X is a halogen atom, and O 5 9 ~ 3.
Concrete examples of such titanium tetravalent compound IB1 include:
titanlum tetrahalldes, such as TiCl4, TlBr4 and TiI4;
alkoxytitanium trihalldes, such as Ti(OCt13)Cl3, Ti(OC2Hs)Cl3, Ti(On-C4Hg)Cl3, T~(oc2tls)Br3~ and Ti(O-lso-C4Hg~Br3;
dlalkoxytitanium dihalldes, such as Tl(OCt13)2Cl2 Tl(OC2~l5)2Cl2l Tl(On-C41~g)2Cl2, and Ti~OC2t15)2Br2; and trialkoxytitanium monohalldes, such as Ti~OC113)3Cl, Ti~OC2tls)3cl~
Ti~On-C4Hg)3Cl, and Ti((OC2Hs)3Br.
21~7634 Of these, preferably used are titanium tetrahalides and particularly preferred is titanium tetrachloride.
These compounds may be used singly or in combination.
The tetravalent titanium compound [B] is used in such 5 an amount that the atomic ratio (Ti/(Mg+Al)) of the titanium (Ti) contained in the compound [B] to the magnesium and the aluminum contained in the solid magnesium aluminum complex [A] is in the range of 0.005 to 18, preferably 0.01 to 15.
The contact of the solid magnesium aluminum complex [A] with the tetravalent titanium compound [B] is carried out preferably in a hydrocarbon solvent. As the hydrocarbon solvent, those similar to the aforesaid hydrocarbons can be employed.
In the invention, the contact is carried out at a temperature of usually 0 to 150 ~C, preferably 50 to 130 ~C, more preferably 50 to 120 ~C.
The titanium catalyst component for ethylene polymerization according to the invention can be obtained in the manner as described above, and it contains, as essential components, magnesium, halogen, aluminum, an alkoxy group and/or alcohol having at least 6 carbon atoms and titanium. The titanium contained in this titanium catalyst component is substantially in a tetravalent state, namely more than 90 %, preferably more than 95 %, most preferably lO0 % of titanium atoms are in the tetravalent state.
2107~31 l9 The atomic ratio Ti/Mg of the titanium catalyst component is in the range of usually 0.01 to 1.5, preferably 0.05 to 1Ø
The atomic ratio Al/Mg of the titanlum catalyst component is in the range of usually 0.1 to 2.0, preferably 0.13 to 1.5, most preferably 0.15 to 1.2.
The molar ratio of alkoxy group and/or alcohol to titanium (OR)/Ti of the titanium catalyst component is in the range of 0.26 to 6.0, preferably 0.26 to 5.0, most preferably 0.26 to 4Ø
The amount of the alkoxy group and/or alcohol having at least 6 carbon atoms is in the range of usually 0.1 to 15 parts by weight, preferably 0.3 to 10 parts by weight, more preferably 0.5 to 6 parts by weight, based on 1 part lS by weight of magnesium.
The titanium catalyst component is preferably in the form of particles, and the particle diameter thereof is preferably in the range of 1 to 200 ~m, more preferably 2 to 100 ~m. The geometrical standard deviation of the titanium catalyst component particles in the particle size distribution is in the range of 1.0 to 2.0, preferably 1.0 to 1.8.
The prepolymerized titanium catalyst component [I]' for ethylene polymerization according to the present invention is obtained by prepolymerizing an olefin to a catalyst comprising [I] the titanium catalyst component as 2i~7~
mentioned above and [II] an organoaluminum compound as mentioned above.
The olefins to be polymerized to the titanium catalyst component [I] include ethylene and ~-olefin having 3-20 carbon atoms aforementioned.
Of these, preferably ethylene is prepolymerized or ethylene and a-olefin having 3-20 carbon atoms or ethylene are prepolymerized.
The catalyst for ethylene polymerization according to the present invention comprises [I] the titanium catalyst component for ethylene polymerization as mentioned above, and [II] the organoaluminum compound as mentioned above.
The another catalyst for ethylene polymerization according to the present invention comprises [I]' the prepolymerized titanium catalyst component as mentioned above, and [II] the organoaluminum compound as mentioned above.
In accordance with the process for ethylene polymerization according to the present invention, ethylene is polymerized or copolymerized with an ~-olefin having 3 to 20 carbon atoms in the presence of a catalyst for ethylene polymerization formed from [I] the above-described titanium catalyst for ethylene polymerizatlon and [II] an organoaluminum compound catalyst component.
Examples of the a-olefins having 3 to 20 carbon atoms to be copolymerized with ethylene includes propylene, 2-210763~
methylpropylene, 1-butene, l-hexene, 1-pentene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-octene, 1-nonene, 1-decene, 1-undecene and 1-dodecene. The a-olefins may be copolymerized with polyenes. Examples of such polyenes S include butadiene, isoprene, 1,4-hexadiene, dicyclopentadiene and 5-ethylidene-2-norbornene.
The copolymer of ethylene with the a-olefin thus obtained contains constituent units derived from ethylene preferably in an amount of at least 90 ~ by mol.
As the organoaluminum compound [II] for use in the polymerization, the aforesaid organoaluminum compound (a-2) used in the preparation of the titanium catalyst component for ethylene polymerization [I] can be employed.
In the polymerization, the titanium catalyst component for ethylene polymerization [I] is used in an amount of generally about 0.00001 to about 1 mmol, preferably about 0.0001 to about 0.1 mmol, in terms of Ti atom, per 1 liter of the polymerization reaction volume.
The organoaluminum compound [II] is used in an amount of 1 to 1,000 mol, preferably 2 to 500 mol, per 1 g-atom of the titanium contained in the titanium catalyst component for ethylene polymerization [I], according to necessity.
The titanium catalyst component for ethylene polymerization may be supported on a carrier. Examples of such a carrier include A12O3, SiO2, B2O3, MgO, CaO, Tio2, ZnO, Zn2O, SnO2, BaO, ThO and resins such as a styrene/divinylbenzene copolymer.
Further, the catalyst for ethylene polymerization as described above may be prepolymerized with ethylene.
Hydrogen may be used in the polymerization stage, whereby a molecular weight of a polymer to be obtained can 5 be regulated.
In the present invention, the polymerization of ethylene may be carried out by either a liquid phase polymerization, such as a solution polymerization and a suspension polymerization, or a gas phase polymerization .
0 Further, the polymerization may be carried out either batchwise, semi-continuously or continuously.
When a slurry polymerization is carried out, any of an inert solvent and ethylene which is liquid at a polymerization temperature may be used as a reaction solvent.
Examples of such inert solvents include aliphatic hydrocarbons, such as propane, butane, n-pentane, isopentane, n-hexane, isohexane, n-heptane, n-octane, isooctane, n-decane, n-dodecane and kerosine; alicyclic hydrocarbons, such as cyclopentane, methylcyclopentane, cyclohexane and methylcyclohexane; and aromatlc hydrocarbons, such as benzene, toluene, xylene and ethylbenzene. These inert solvents may be used singly of in combination.
The polymerization temperature is in the range of usually 20 to 150 ~C, preferably 50 to 120 ~C, more preferably 70 to 110 ~C; and the polymerization pressure is in the range of usually 1 to 1,000 kg/cm2, preferably 2 to 40 kg/cm2.
The copolymerization may be carried out in plural steps.
The ethylene polymer obtained as above may be either a homopolymer of ethylene, an ethylene/~-olefin random copolymer or a block copolymer, but preferred are a homopolymer of ethylene and a random copolymer of ethylene with an ~-olefin.
0 Particularly preferably, an ethylene homopolymer or an ethylene/a-olefin copolymer, having a density of 0.900 to 0.970 g/cm3, preferably 0.910 to 0.970 g/cm3, is prepared in the present invention. The density used herein is that determined in accordance with ASTM D1505.
According to the present invention as described above, ethylene can be (co)polymerized with a high polymerization activity, and moreover, ethylene can be copolymerized with an ~-olefin of 3 to 20 carbon atoms.
In the invention, the ethylene (co)polymer is obtained in the form of particles, and the particle diameter is in the range of generally 10 to 1,500 ~m, preferably 10 to 1,000 ~m.
The geometrical standard deviation of the particles is in the range of 1.0 to 2.0, preferably 1.0 to 1.8.
The ethylene (co)polymer obtained as above according to the present invention has a narrow particle size distribution.
21~763~
In the powdery (co)polymer of the present invention, it is desired that the particles having a diameter of not smaller than 850 ~m are contained in an amount of not more than 1.0 % by weight, preferably not more than 0.8 % by weight, particularly preferably not more than 0.5 % by weight; the particles having a diameter of not larger than 100 ~m are contained in an amount of not more 7.0 % by weight, preferably not more than 5.0 % by weight, particularly preferably not more than 3.0 % by weight; and the particles having a diameter of 100 to 500 ~m are contained in an amount of not less than 85 % by weight, preferably not less than 90 % by weight; each being based on the total weight of the particles.
The ethylene (co)polymer obtained in the invention may contain various additives, such as heat stabilizers, weathering stabilizers, antistatic agents, anti-blocking agents, lubricants, nucleating agents, pigments, dyes, inorganic fillers and organic fillers.
EFFECT OF THE INVENTION
In the titanium catalyst component for ethylene polymerization according to the present invention, the halogen-containing titanium compound is supported on the solid magnesium aluminum complex, and the titanium contained in this catalyst component is in a tetravalent state. Hence, use of the titanium catalyst component makes it possible to polymerize ethylene with a high 2107~34 polymerization activity, and moreover, when ethylene is copolymerized with an ~-olefin of 3 to 20 carbon atoms, an ethylene copolymer having a narrow particle size distribution can be prepared.
Specifically, by the use of the titanium catalyst component for ethylene polymerization, ethylene (co)polymer particles having a narrow particle size distribution can be obtained, and extremely small sized particles are produced in only a small amount.
The process for ethylene (co)polymerization according to the present invention is carried out using such titanium catalyst component for ethylene polymerization as described above to provide an ethylene (co)polymer having a narrow particle size distributlon and excellent morphology with a high polymerization activity. When the polymerization is carried out in a slurry polymerization, a slurry-handling property is also excellent.
EXAMPLE
The present invention will be described below in more detail with reference to examples, but it should be construed that the invention is in no way limited to those examples.
Analysis of the catalyst for ethylene polymerization and measurements of the particle size distribution and further the geometrical standard deviation are carried out in the following manner.
21076~
1. Mg, Al, Ti Content determination of Mg, Al and Ti was carried out by ICP analysis using an analyzer (ICPFlOOOTR, produced by Shimazu Seisakusho K.K.).
2. Cl Content determination of Cl was carried out by a silver nitrate titration method.
3. OR group Content determination of OR group (or alcohol) was carried out as follows.
A well dried catalyst was added to an acetone solution containing 10 % by weight of water to undergo hydrolysis so as to obtain ROH, and the ROH was determined by means of gas chromatography.
(9) compounds of the formula RanAl(NRe2)3-n, such as Me2AlNEt2, Et2AlNHMe, Me2AlNHEt, Et2AlN(Me3Si)2 and (iso-Bu)2AlN(Me3si)2;
(5) compounds of the formula RanAl(SiRf3)3-n, such as (iso-Bu)2AlSiMe3; and (6) compounds of the formula RanAl[N(Rg)AlRh2]3-n, such as Et2AlN(Me)AlEt2 and (iso-Bu)2AlN(Et)Al(iso-Bu)2.
In addition, also employable as the the organoaluminum compound (a-2) is a complex alkylate which is formed from a metal of Group I of the periodic table and aluminum, said complex alkylate being represented by the following formula:
MlAlR i 4 wherein M1 is Li, Na or K, and Rj is a hydrocarbon group of 1 to 15 carbon atoms.
Concrete examples of such complex alkylate include LiAl(C2H5)4 and LiAl(C7H1s)4.
Of the organoaluminum compounds as exemplified above, preferably used are trialkylaluminum, dialkylaluminum halide, dialkylaluminum hydride and dialkylaluminum alkoxide. Of these, trialkylaluminum, particularly triethylaluminum, is preferred because a catalyst with a favorable shape can be obtained by using it.
2i~763~
l6 These organoaluminum compounds may be used alone or in combination.
For forming the solid magnesium aluminum complex [A], the organoaluminum compound (a-2) is desirably used in such S an amount that the molar ratio (ROH/Al) of the alcohol (ROH) having at least 6 carbon atoms used for the preparation of the magnesium solution (a-l) to the aluminum atom (Al) contained in the organoaluminum compound (a-2) is in the range of about 0.5 to 7, preferably 1 to 5.
The contact of the magnesium solution (a-l) with the organoaluminum compound (a-2) can be carried out by dropwise adding the organoaluminum compound (a-2) slowly to the magnesium solution (a-l) having a magnesium concentration of preferably 0.005 to 2 mol/l, more preferably 0.05 to 1 mol/l, with stirring of the magnesium solution. In this manner, a solid magnesium aluminum complex [A] having excellent particle properties (excellent morphology) can be obtained.
The temperature for contacting the magnesium solution (a-l) with the organoaluminum compound (a-2) is in the range of usually -50 to 150 ~C, preferably -30 to 100 ~C.
The solid magnesium aluminum complex [A] thus obtained contains no reducing organic group, and hence it exhibits no reduction ability.
The titanium catalyst component for ethylene polymerization [I] according to the present invention is obtained by contactlng the above-described solid magnesium aluml1)u1n complex ~A; wl~h a tetravalent cornpound l~.
Preferably used as the tetravalent titanium compound [Bl is a compound represented by the follow~ng formula (ll):
Tl(OR2)9X4_9 (ll) wherein ~ is a hydrocarbon group, X is a halogen atom, and O 5 9 ~ 3.
Concrete examples of such titanium tetravalent compound IB1 include:
titanlum tetrahalldes, such as TiCl4, TlBr4 and TiI4;
alkoxytitanium trihalldes, such as Ti(OCt13)Cl3, Ti(OC2Hs)Cl3, Ti(On-C4Hg)Cl3, T~(oc2tls)Br3~ and Ti(O-lso-C4Hg~Br3;
dlalkoxytitanium dihalldes, such as Tl(OCt13)2Cl2 Tl(OC2~l5)2Cl2l Tl(On-C41~g)2Cl2, and Ti~OC2t15)2Br2; and trialkoxytitanium monohalldes, such as Ti~OC113)3Cl, Ti~OC2tls)3cl~
Ti~On-C4Hg)3Cl, and Ti((OC2Hs)3Br.
21~7634 Of these, preferably used are titanium tetrahalides and particularly preferred is titanium tetrachloride.
These compounds may be used singly or in combination.
The tetravalent titanium compound [B] is used in such 5 an amount that the atomic ratio (Ti/(Mg+Al)) of the titanium (Ti) contained in the compound [B] to the magnesium and the aluminum contained in the solid magnesium aluminum complex [A] is in the range of 0.005 to 18, preferably 0.01 to 15.
The contact of the solid magnesium aluminum complex [A] with the tetravalent titanium compound [B] is carried out preferably in a hydrocarbon solvent. As the hydrocarbon solvent, those similar to the aforesaid hydrocarbons can be employed.
In the invention, the contact is carried out at a temperature of usually 0 to 150 ~C, preferably 50 to 130 ~C, more preferably 50 to 120 ~C.
The titanium catalyst component for ethylene polymerization according to the invention can be obtained in the manner as described above, and it contains, as essential components, magnesium, halogen, aluminum, an alkoxy group and/or alcohol having at least 6 carbon atoms and titanium. The titanium contained in this titanium catalyst component is substantially in a tetravalent state, namely more than 90 %, preferably more than 95 %, most preferably lO0 % of titanium atoms are in the tetravalent state.
2107~31 l9 The atomic ratio Ti/Mg of the titanium catalyst component is in the range of usually 0.01 to 1.5, preferably 0.05 to 1Ø
The atomic ratio Al/Mg of the titanlum catalyst component is in the range of usually 0.1 to 2.0, preferably 0.13 to 1.5, most preferably 0.15 to 1.2.
The molar ratio of alkoxy group and/or alcohol to titanium (OR)/Ti of the titanium catalyst component is in the range of 0.26 to 6.0, preferably 0.26 to 5.0, most preferably 0.26 to 4Ø
The amount of the alkoxy group and/or alcohol having at least 6 carbon atoms is in the range of usually 0.1 to 15 parts by weight, preferably 0.3 to 10 parts by weight, more preferably 0.5 to 6 parts by weight, based on 1 part lS by weight of magnesium.
The titanium catalyst component is preferably in the form of particles, and the particle diameter thereof is preferably in the range of 1 to 200 ~m, more preferably 2 to 100 ~m. The geometrical standard deviation of the titanium catalyst component particles in the particle size distribution is in the range of 1.0 to 2.0, preferably 1.0 to 1.8.
The prepolymerized titanium catalyst component [I]' for ethylene polymerization according to the present invention is obtained by prepolymerizing an olefin to a catalyst comprising [I] the titanium catalyst component as 2i~7~
mentioned above and [II] an organoaluminum compound as mentioned above.
The olefins to be polymerized to the titanium catalyst component [I] include ethylene and ~-olefin having 3-20 carbon atoms aforementioned.
Of these, preferably ethylene is prepolymerized or ethylene and a-olefin having 3-20 carbon atoms or ethylene are prepolymerized.
The catalyst for ethylene polymerization according to the present invention comprises [I] the titanium catalyst component for ethylene polymerization as mentioned above, and [II] the organoaluminum compound as mentioned above.
The another catalyst for ethylene polymerization according to the present invention comprises [I]' the prepolymerized titanium catalyst component as mentioned above, and [II] the organoaluminum compound as mentioned above.
In accordance with the process for ethylene polymerization according to the present invention, ethylene is polymerized or copolymerized with an ~-olefin having 3 to 20 carbon atoms in the presence of a catalyst for ethylene polymerization formed from [I] the above-described titanium catalyst for ethylene polymerizatlon and [II] an organoaluminum compound catalyst component.
Examples of the a-olefins having 3 to 20 carbon atoms to be copolymerized with ethylene includes propylene, 2-210763~
methylpropylene, 1-butene, l-hexene, 1-pentene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-octene, 1-nonene, 1-decene, 1-undecene and 1-dodecene. The a-olefins may be copolymerized with polyenes. Examples of such polyenes S include butadiene, isoprene, 1,4-hexadiene, dicyclopentadiene and 5-ethylidene-2-norbornene.
The copolymer of ethylene with the a-olefin thus obtained contains constituent units derived from ethylene preferably in an amount of at least 90 ~ by mol.
As the organoaluminum compound [II] for use in the polymerization, the aforesaid organoaluminum compound (a-2) used in the preparation of the titanium catalyst component for ethylene polymerization [I] can be employed.
In the polymerization, the titanium catalyst component for ethylene polymerization [I] is used in an amount of generally about 0.00001 to about 1 mmol, preferably about 0.0001 to about 0.1 mmol, in terms of Ti atom, per 1 liter of the polymerization reaction volume.
The organoaluminum compound [II] is used in an amount of 1 to 1,000 mol, preferably 2 to 500 mol, per 1 g-atom of the titanium contained in the titanium catalyst component for ethylene polymerization [I], according to necessity.
The titanium catalyst component for ethylene polymerization may be supported on a carrier. Examples of such a carrier include A12O3, SiO2, B2O3, MgO, CaO, Tio2, ZnO, Zn2O, SnO2, BaO, ThO and resins such as a styrene/divinylbenzene copolymer.
Further, the catalyst for ethylene polymerization as described above may be prepolymerized with ethylene.
Hydrogen may be used in the polymerization stage, whereby a molecular weight of a polymer to be obtained can 5 be regulated.
In the present invention, the polymerization of ethylene may be carried out by either a liquid phase polymerization, such as a solution polymerization and a suspension polymerization, or a gas phase polymerization .
0 Further, the polymerization may be carried out either batchwise, semi-continuously or continuously.
When a slurry polymerization is carried out, any of an inert solvent and ethylene which is liquid at a polymerization temperature may be used as a reaction solvent.
Examples of such inert solvents include aliphatic hydrocarbons, such as propane, butane, n-pentane, isopentane, n-hexane, isohexane, n-heptane, n-octane, isooctane, n-decane, n-dodecane and kerosine; alicyclic hydrocarbons, such as cyclopentane, methylcyclopentane, cyclohexane and methylcyclohexane; and aromatlc hydrocarbons, such as benzene, toluene, xylene and ethylbenzene. These inert solvents may be used singly of in combination.
The polymerization temperature is in the range of usually 20 to 150 ~C, preferably 50 to 120 ~C, more preferably 70 to 110 ~C; and the polymerization pressure is in the range of usually 1 to 1,000 kg/cm2, preferably 2 to 40 kg/cm2.
The copolymerization may be carried out in plural steps.
The ethylene polymer obtained as above may be either a homopolymer of ethylene, an ethylene/~-olefin random copolymer or a block copolymer, but preferred are a homopolymer of ethylene and a random copolymer of ethylene with an ~-olefin.
0 Particularly preferably, an ethylene homopolymer or an ethylene/a-olefin copolymer, having a density of 0.900 to 0.970 g/cm3, preferably 0.910 to 0.970 g/cm3, is prepared in the present invention. The density used herein is that determined in accordance with ASTM D1505.
According to the present invention as described above, ethylene can be (co)polymerized with a high polymerization activity, and moreover, ethylene can be copolymerized with an ~-olefin of 3 to 20 carbon atoms.
In the invention, the ethylene (co)polymer is obtained in the form of particles, and the particle diameter is in the range of generally 10 to 1,500 ~m, preferably 10 to 1,000 ~m.
The geometrical standard deviation of the particles is in the range of 1.0 to 2.0, preferably 1.0 to 1.8.
The ethylene (co)polymer obtained as above according to the present invention has a narrow particle size distribution.
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In the powdery (co)polymer of the present invention, it is desired that the particles having a diameter of not smaller than 850 ~m are contained in an amount of not more than 1.0 % by weight, preferably not more than 0.8 % by weight, particularly preferably not more than 0.5 % by weight; the particles having a diameter of not larger than 100 ~m are contained in an amount of not more 7.0 % by weight, preferably not more than 5.0 % by weight, particularly preferably not more than 3.0 % by weight; and the particles having a diameter of 100 to 500 ~m are contained in an amount of not less than 85 % by weight, preferably not less than 90 % by weight; each being based on the total weight of the particles.
The ethylene (co)polymer obtained in the invention may contain various additives, such as heat stabilizers, weathering stabilizers, antistatic agents, anti-blocking agents, lubricants, nucleating agents, pigments, dyes, inorganic fillers and organic fillers.
EFFECT OF THE INVENTION
In the titanium catalyst component for ethylene polymerization according to the present invention, the halogen-containing titanium compound is supported on the solid magnesium aluminum complex, and the titanium contained in this catalyst component is in a tetravalent state. Hence, use of the titanium catalyst component makes it possible to polymerize ethylene with a high 2107~34 polymerization activity, and moreover, when ethylene is copolymerized with an ~-olefin of 3 to 20 carbon atoms, an ethylene copolymer having a narrow particle size distribution can be prepared.
Specifically, by the use of the titanium catalyst component for ethylene polymerization, ethylene (co)polymer particles having a narrow particle size distribution can be obtained, and extremely small sized particles are produced in only a small amount.
The process for ethylene (co)polymerization according to the present invention is carried out using such titanium catalyst component for ethylene polymerization as described above to provide an ethylene (co)polymer having a narrow particle size distributlon and excellent morphology with a high polymerization activity. When the polymerization is carried out in a slurry polymerization, a slurry-handling property is also excellent.
EXAMPLE
The present invention will be described below in more detail with reference to examples, but it should be construed that the invention is in no way limited to those examples.
Analysis of the catalyst for ethylene polymerization and measurements of the particle size distribution and further the geometrical standard deviation are carried out in the following manner.
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1. Mg, Al, Ti Content determination of Mg, Al and Ti was carried out by ICP analysis using an analyzer (ICPFlOOOTR, produced by Shimazu Seisakusho K.K.).
2. Cl Content determination of Cl was carried out by a silver nitrate titration method.
3. OR group Content determination of OR group (or alcohol) was carried out as follows.
A well dried catalyst was added to an acetone solution containing 10 % by weight of water to undergo hydrolysis so as to obtain ROH, and the ROH was determined by means of gas chromatography.
4. Particle size distribution and geometrical standard deviation The particle size distribution and the geometrical standard deviation were measured by the use of a vibrator (low-tap type, produced by Iida Seisakusho K.K.) and a sieve (Iida lasting sieve of JIS-Z-8801, inner diameter:
200 mm).
Example 1 [Preparation of a catalyst component]
4.8 g of a commercially available magnesium chloride anhydride, 19.5 g of 2-ethylhexanol and 200 ml of decane were heated at 140 ~C for 3 hours to give a homogeneous 21~7~i solution containing the magnesium chloride. To the solution, a mixture solution composed of 60 mmol of triethylaluminum and 52 ml of decane was dropwise added at 20 ~C over 30 minutes while stirring. Then, the temperature of the resulting mixture was elevated to 80 ~C
over 2 hours and heated at the same temperature for 2 hours. After completion of the reaction under heating, a solid portion was separated by filtration and washed once with 200 ml of decane, to obtain a solid magnesium aluminum 0 complex.
The solid magnesium aluminum complex thus obtained was suspended again in 200 ml of decane, and to the resulting suspension was added 400 mmol of titanium tetrachloride to perform reaction at 80 ~C for 2 hours. Then, the reaction product was well washed with hexane to obtain a hexane suspension of a solid catalyst. The composition of the solid catalyst is set forth in Table 2.
A portion (corresponding to 5 g of the solid catalyst) of the hexane suspension of the solid catalyst was withdrawn and this portion was introduced into a 300 ml reactor equipped with a Teflon stirrer. To the reactor was further added 0.5 g of liquid paraffin, and the content of the reactor was stirred. Then, the reactor was placed in a bath of 40 ~C while causing nitrogen to pass through the reactor at a rate of 80 Nl/Hr, to evaporate hexane. By the evaporation, a powdery Ti catalyst component containing about 10 % of liquid paraffin was obtained.
2107~34 [Polymerization]
A 2-liter autoclave was charged with 1 liter of purified hexane in a nitrogen atmosphere. Then, 1.0 mmol of triethylaluminum and the powdery Ti catalyst component obtained ln the above were suspended in hexane, and 0.1 mmol (in terms of Ti atom) of the resulting suspension was added to the polymerizer. The temperature of the system was elevated to 80 ~C, and to the polymerizer was fed 4.0 kg/cm2G of hydrogen and was then further fed ethylene continuously over 2 hours so that the total pressure was kept at 8.0 kg/cm2G. The temperature during the polymerization was kept at 80 ~C.
After the polymerization was completed, an ethylene polymer produced was separated from the hexane solvent and dried.
The results of measurements on the properties of the ethylene polymer are set forth in Table 3.
The yield of the powdery polymer obtained was 227 g, and the polymer had MFR of 2.7 g/10 min and an apparent bulk specific gravity of 0.33 g/cc.
The particle size distribution of the powdery polymer is set forth in Table 1.
Table 1 > 850 ~m 850 ~m 500 ~m250 ~m180 ~m100 ~m < 45 ~m 500 ~m 250 ~m180 ~m100 ~m 45 ~m 0 0.4 93.1 4.1 1.8 0.6 0 wt.% wt.%wt.% wt.% wt.%
Example 2 Preparation of a catalyst component and polymerization were carried out in a manner similar to that of Example 1 except for varying the amount of 2-ethylhexanol from 19.5 g to 16.3 g and the amount of triethylaluminum from 60 mmol to 46 mmol.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Example 3 Preparation of a catalyst component and polymerization lS were carried out in a manner similar to that of Example 2 except for varying the temperature condition after addition of 400 mmol of titanium tetrachloride from 80 ~C to 100 ~C.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Example 4 Preparation of a catalyst component and polymerization were carried out in a manner similar to that of Example 1 2107~3 1 except for varying the amount of 2-ethylhexanol from 19.5 g to 16.3 g and the amount of triethylaluminum from 60 mmol to 43 mmol.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Example 5 Preparation of a catalyst component and polymerization were carried out in a manner similar to that of Example 1 0 except for varying the amount of 2-ethylhexanol from 19.5 g to 15.3 g and the amount of triethylaluminum from 60 mmol to 41 mmol.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Comparative Example 1 4.8 g of a commercially available magnesium chloride anhydride, 19.5 g of 2-ethylhexanol and 200 ml of decane were heated at 140 ~C for 3 hours to give a homogeneous solution containing magnesium chloride. To the solution, a mixture solution composed of 52 mmol of triethylaluminum and 45 ml of decane was dropwise added at 20 ~C over 30 minutes while stirring. Then, the temperature of the resulting mixture was elevated to 80 ~C over 2.5 hours and heated at 80 ~C for 1 hour. After completion of the reaction under heating, the reaction slurry was allowed to stand, then the supernatant was removed, and to the 2 10 7~e3~il remaining slurry containing a solid portion produced in the above reaction were added 200 ml of decane and 50 mmol of diethylaluminum chloride to perform reaction again at 80 ~C
for 1 hour. Subsequently, the solid portion was separated 5 by filtration and washed once with 100 ml of decane, to prepare a solid component contalning an organic group having reduction ability.
The solid component thus obtained was suspended again in 200 ml of decane, and to the resulting suspension was then added 25 mmol of titanium tetrachloride to perform reaction at 80 ~C for 2 hours. Thereafter, a solid produced by the reaction was separated by filtration and washed 5 times with hexane, to obtain a titanium catalyst component.
Using the titanium catalyst component thus obtained, ethylene was polymerized in a manner similar to that of Example 1.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
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Table 2 Composition of the solid catalyst Molar (wt.%) ratio of Ti4 Ti3+/Ti4~ Mg Al Cl OR OR/Ti Ex.1 7.3 0 8.8 5.0 5310.5 0.53 Ex.2 7.0 0 10.2 4.7 5012.8 0.67 Ex.3 7.0 0 8.6 4.0 60 5.3 0.28 Ex.4 6.7 0 9.2 4.4 5311.4 0.63 Ex.5 6.7 0 9.8 4.6 5012.9 0.71 Comp.Ex.1 5 7 12.0 0.743 34 2.20 Remark OR: alkoxy group and/or alcohol s 2 1076~1 Table 3 Activity MFR BulkParticle Size SpecificDistribution Geometri-Gravity (wt.%~ cal lOO~m Standard g-PE/g- g/lOmlng/cc >500~m ~ <lOO~m Deviation catalyst 500~m Ex. 1 34,600 2.7 0.33 0.4 99.0 0.6 1.56 Ex. 2 36,900 4.4 0.32 0 98.9 1.1 1.51 Ex. 3 33,000 4.9 0.31 0.7 98.0 1.5 1.60 Ex. 4 31,200 5.7 0.30 0.3 98.8 0.8 1.64 Ex. 5 33,900 4.5 0.30 0.2 98.2 1.6 1.54 Comp. 10,600 2.8 0.30 1.1 98.1 0.9 1.54 Ex. 1 Comparative Example 2 [Catalyst]
30 mmol of a commercially available magnesium chloride anhydride was suspended in 150 ml of n-decane. To the resultant suspension was dropwise added 120 mmol of n-butanol over 1 hour with stirring of the suspension, to perform reaction at 80 ~C for 3 hours. Then, to the suspension was further dropwise added 240 mmol of diethylaluminum monochloride at room temperature to perform reaction at 90 ~C for 3 hours. The solid portion obtained in the reaction was washed and then suspended in n-decane to give a n-decane suspension. To the suspension was 21076~
dropwise added 3 mmol of titanium tetrachloride to perform reaction at 25 ~C for 10 minutes.
The composition of catalyst thus obtained is set forth in Table 4.
[Polymerization]
A stainless autoclave with a content volume of 2 liters was thoroughly purged with nitrogen, then charged with 1 liter of n-hexane and heated to 50 ~C. Thereafter, to the autoclave were added 1.0 mmol of triisobutylaluminum, 0.5 mmol of ethylene dichloride and 0.02 mmol (in terms of Ti atom) of the catalyst obtained in the above. After sealing of the autoclave, to the autoclave were fed hydrogen so that the gauge pressure was 4.5 kg/cm3 and then further fed ethylene so that the gauge pressure was 8 kg/cm3. The reaction system was kept at 80 ~C for 2 hours while continuously feeding ethylene to the autoclave to keep the total pressure at 8 kg/cm3-G.
The yield of polyethylene thus obtained was 316 g.
This amount corresponds to a polymerization activity of 16,800 g-PE/g-catalyst.
Table 4 Composition of the solid catalyst Molar (wt.%) ratio of Ti3+ Ti4+ Ti3+/Ti4+ Mg Al Cl OR oR/Ti Comp. 3.6 1.5 2.4 17 4.2 701.4 0.10 Ex. 2 2 ~
Example 6 [Prepolymerlzation]
A 400 ml cylindrical flask equipped with a stirrer was charged with 200 ml of purified hexane, 6 mmol of 5 triethylaluminum and 2 mmol (in terms of Ti atom) of a hexane suspension of the powdery titanium catalyst component obtained in Example 1. Thereafter, to the flask was fed ethylene at a feed rate of 1.74 Nl/hour over 3 hours at 20 ~C to perform prepolymerization of the catalyst component with ethylene. The amount of polyethylene produced was 5 g based on 1 g of the catalyst.
[Polymerization]
A 2-liter autoclave was charged with 1 liter of purified hexane in a nitrogen atmosphere. To the autoclave were then added 1.0 mmol of triethylaluminum and 0.01 mmol (in terms of Ti atom) of the catalyst component having been subjected to the prepolymerization in the above stage, and the temperature of the system was elevated to 80 ~C.
Thereafter, to the autoclave was fed hydrogen so that the pressure in the system was 4.0 kg/cm2-G, and was further fed ethylene continuously for 2 hours so that the total pressure was 8.0 kg/cm2-G. The temperature during the polymerization stage was kept at 80 ~C. After the polymerization was completed, an ethylene polymer produced was separated from the hexane solvent and dried.
The results of measurement on the properties of the polymer are set forth in Table 5.
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Table 5 Actlv- MFRBulk Particle Size ity Specif- Distribution Gravity g-PE/g- g/lOmin g/cc >500~m lOO~m SlOO~m cata-lyst 500~m Ex. 6 32,800 2.3 0.34 0.6 98.5 0.9 Comparative Example 3 In a 400 ml four-neck flask, 30 mmol of magnesium chloride anhydride was suspended in 150 ml of n-decane. To the resultant suspension was dropwise added 180 mmol of ethanol over 1 hour with stirring of the suspension, to perform reaction at room temperature for 1 hour. Through 0 the reaction, a white powder was obtained from a swollen magnesium chloride. Then, to the reaction system was dropwise added 84 mmol of diethylaluminum monochloride at room temperature to perform reaction at 30 ~C for 1 hour.
Thereafter, 300 mmol of titanium tetrachloride was added to the reaction system, and the temperature of the system was elevated to 80 ~C to perform reaction for 3 hours while stirring the reaction solution. After the reaction was completed, a solid portion was separated from the solution, and the solid portion was washed with 2 liters of n-decane.
[Polymerization]
2107i~
A 2-liter stainless steel autoclave was thoroughly purged with nitrogen. Then, the autoclave was charged with 1 liter of n-hexane and was heated to 50 ~C. To the autoclave were added 1.0 mmol of trilsobutylaluminum, 0.5 5 mmol of ethylene dlchlorlde and 0.02 mmol (ln terms of T1 atom) of the catalyst obtained in the above, and the autoclave was sealed. Thereafter, into the autoclave was pressed hydrogen until the gauge pressure became 4.5 kg/cm2, and was further pressed ethylene until the gauge pressure became 8 kg/cm2. Then, to the autoclave was contlnuously fed ethylene at 80 ~C for 2 hours so that the total pressure was kept at 8 kg/cm2-G.
The results of measurements on the propertles of the polymer obtained are set forth in Table 6.
Table 6 Activity MFR Bulk Particle Size SpecificDistributionGeometri-Gravity(wt.~) cal 100~m Standard g-PE/g- g/lOming/cc >500~m ~ <100~m Deviation catalyst 500~m Comp. 36,600 3.0 0.31 17.6 65.8 16.5 2.29 Ex. 3
200 mm).
Example 1 [Preparation of a catalyst component]
4.8 g of a commercially available magnesium chloride anhydride, 19.5 g of 2-ethylhexanol and 200 ml of decane were heated at 140 ~C for 3 hours to give a homogeneous 21~7~i solution containing the magnesium chloride. To the solution, a mixture solution composed of 60 mmol of triethylaluminum and 52 ml of decane was dropwise added at 20 ~C over 30 minutes while stirring. Then, the temperature of the resulting mixture was elevated to 80 ~C
over 2 hours and heated at the same temperature for 2 hours. After completion of the reaction under heating, a solid portion was separated by filtration and washed once with 200 ml of decane, to obtain a solid magnesium aluminum 0 complex.
The solid magnesium aluminum complex thus obtained was suspended again in 200 ml of decane, and to the resulting suspension was added 400 mmol of titanium tetrachloride to perform reaction at 80 ~C for 2 hours. Then, the reaction product was well washed with hexane to obtain a hexane suspension of a solid catalyst. The composition of the solid catalyst is set forth in Table 2.
A portion (corresponding to 5 g of the solid catalyst) of the hexane suspension of the solid catalyst was withdrawn and this portion was introduced into a 300 ml reactor equipped with a Teflon stirrer. To the reactor was further added 0.5 g of liquid paraffin, and the content of the reactor was stirred. Then, the reactor was placed in a bath of 40 ~C while causing nitrogen to pass through the reactor at a rate of 80 Nl/Hr, to evaporate hexane. By the evaporation, a powdery Ti catalyst component containing about 10 % of liquid paraffin was obtained.
2107~34 [Polymerization]
A 2-liter autoclave was charged with 1 liter of purified hexane in a nitrogen atmosphere. Then, 1.0 mmol of triethylaluminum and the powdery Ti catalyst component obtained ln the above were suspended in hexane, and 0.1 mmol (in terms of Ti atom) of the resulting suspension was added to the polymerizer. The temperature of the system was elevated to 80 ~C, and to the polymerizer was fed 4.0 kg/cm2G of hydrogen and was then further fed ethylene continuously over 2 hours so that the total pressure was kept at 8.0 kg/cm2G. The temperature during the polymerization was kept at 80 ~C.
After the polymerization was completed, an ethylene polymer produced was separated from the hexane solvent and dried.
The results of measurements on the properties of the ethylene polymer are set forth in Table 3.
The yield of the powdery polymer obtained was 227 g, and the polymer had MFR of 2.7 g/10 min and an apparent bulk specific gravity of 0.33 g/cc.
The particle size distribution of the powdery polymer is set forth in Table 1.
Table 1 > 850 ~m 850 ~m 500 ~m250 ~m180 ~m100 ~m < 45 ~m 500 ~m 250 ~m180 ~m100 ~m 45 ~m 0 0.4 93.1 4.1 1.8 0.6 0 wt.% wt.%wt.% wt.% wt.%
Example 2 Preparation of a catalyst component and polymerization were carried out in a manner similar to that of Example 1 except for varying the amount of 2-ethylhexanol from 19.5 g to 16.3 g and the amount of triethylaluminum from 60 mmol to 46 mmol.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Example 3 Preparation of a catalyst component and polymerization lS were carried out in a manner similar to that of Example 2 except for varying the temperature condition after addition of 400 mmol of titanium tetrachloride from 80 ~C to 100 ~C.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Example 4 Preparation of a catalyst component and polymerization were carried out in a manner similar to that of Example 1 2107~3 1 except for varying the amount of 2-ethylhexanol from 19.5 g to 16.3 g and the amount of triethylaluminum from 60 mmol to 43 mmol.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Example 5 Preparation of a catalyst component and polymerization were carried out in a manner similar to that of Example 1 0 except for varying the amount of 2-ethylhexanol from 19.5 g to 15.3 g and the amount of triethylaluminum from 60 mmol to 41 mmol.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
Comparative Example 1 4.8 g of a commercially available magnesium chloride anhydride, 19.5 g of 2-ethylhexanol and 200 ml of decane were heated at 140 ~C for 3 hours to give a homogeneous solution containing magnesium chloride. To the solution, a mixture solution composed of 52 mmol of triethylaluminum and 45 ml of decane was dropwise added at 20 ~C over 30 minutes while stirring. Then, the temperature of the resulting mixture was elevated to 80 ~C over 2.5 hours and heated at 80 ~C for 1 hour. After completion of the reaction under heating, the reaction slurry was allowed to stand, then the supernatant was removed, and to the 2 10 7~e3~il remaining slurry containing a solid portion produced in the above reaction were added 200 ml of decane and 50 mmol of diethylaluminum chloride to perform reaction again at 80 ~C
for 1 hour. Subsequently, the solid portion was separated 5 by filtration and washed once with 100 ml of decane, to prepare a solid component contalning an organic group having reduction ability.
The solid component thus obtained was suspended again in 200 ml of decane, and to the resulting suspension was then added 25 mmol of titanium tetrachloride to perform reaction at 80 ~C for 2 hours. Thereafter, a solid produced by the reaction was separated by filtration and washed 5 times with hexane, to obtain a titanium catalyst component.
Using the titanium catalyst component thus obtained, ethylene was polymerized in a manner similar to that of Example 1.
The results of measurements on the properties of the polymer obtained are set forth in Table 3.
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Table 2 Composition of the solid catalyst Molar (wt.%) ratio of Ti4 Ti3+/Ti4~ Mg Al Cl OR OR/Ti Ex.1 7.3 0 8.8 5.0 5310.5 0.53 Ex.2 7.0 0 10.2 4.7 5012.8 0.67 Ex.3 7.0 0 8.6 4.0 60 5.3 0.28 Ex.4 6.7 0 9.2 4.4 5311.4 0.63 Ex.5 6.7 0 9.8 4.6 5012.9 0.71 Comp.Ex.1 5 7 12.0 0.743 34 2.20 Remark OR: alkoxy group and/or alcohol s 2 1076~1 Table 3 Activity MFR BulkParticle Size SpecificDistribution Geometri-Gravity (wt.%~ cal lOO~m Standard g-PE/g- g/lOmlng/cc >500~m ~ <lOO~m Deviation catalyst 500~m Ex. 1 34,600 2.7 0.33 0.4 99.0 0.6 1.56 Ex. 2 36,900 4.4 0.32 0 98.9 1.1 1.51 Ex. 3 33,000 4.9 0.31 0.7 98.0 1.5 1.60 Ex. 4 31,200 5.7 0.30 0.3 98.8 0.8 1.64 Ex. 5 33,900 4.5 0.30 0.2 98.2 1.6 1.54 Comp. 10,600 2.8 0.30 1.1 98.1 0.9 1.54 Ex. 1 Comparative Example 2 [Catalyst]
30 mmol of a commercially available magnesium chloride anhydride was suspended in 150 ml of n-decane. To the resultant suspension was dropwise added 120 mmol of n-butanol over 1 hour with stirring of the suspension, to perform reaction at 80 ~C for 3 hours. Then, to the suspension was further dropwise added 240 mmol of diethylaluminum monochloride at room temperature to perform reaction at 90 ~C for 3 hours. The solid portion obtained in the reaction was washed and then suspended in n-decane to give a n-decane suspension. To the suspension was 21076~
dropwise added 3 mmol of titanium tetrachloride to perform reaction at 25 ~C for 10 minutes.
The composition of catalyst thus obtained is set forth in Table 4.
[Polymerization]
A stainless autoclave with a content volume of 2 liters was thoroughly purged with nitrogen, then charged with 1 liter of n-hexane and heated to 50 ~C. Thereafter, to the autoclave were added 1.0 mmol of triisobutylaluminum, 0.5 mmol of ethylene dichloride and 0.02 mmol (in terms of Ti atom) of the catalyst obtained in the above. After sealing of the autoclave, to the autoclave were fed hydrogen so that the gauge pressure was 4.5 kg/cm3 and then further fed ethylene so that the gauge pressure was 8 kg/cm3. The reaction system was kept at 80 ~C for 2 hours while continuously feeding ethylene to the autoclave to keep the total pressure at 8 kg/cm3-G.
The yield of polyethylene thus obtained was 316 g.
This amount corresponds to a polymerization activity of 16,800 g-PE/g-catalyst.
Table 4 Composition of the solid catalyst Molar (wt.%) ratio of Ti3+ Ti4+ Ti3+/Ti4+ Mg Al Cl OR oR/Ti Comp. 3.6 1.5 2.4 17 4.2 701.4 0.10 Ex. 2 2 ~
Example 6 [Prepolymerlzation]
A 400 ml cylindrical flask equipped with a stirrer was charged with 200 ml of purified hexane, 6 mmol of 5 triethylaluminum and 2 mmol (in terms of Ti atom) of a hexane suspension of the powdery titanium catalyst component obtained in Example 1. Thereafter, to the flask was fed ethylene at a feed rate of 1.74 Nl/hour over 3 hours at 20 ~C to perform prepolymerization of the catalyst component with ethylene. The amount of polyethylene produced was 5 g based on 1 g of the catalyst.
[Polymerization]
A 2-liter autoclave was charged with 1 liter of purified hexane in a nitrogen atmosphere. To the autoclave were then added 1.0 mmol of triethylaluminum and 0.01 mmol (in terms of Ti atom) of the catalyst component having been subjected to the prepolymerization in the above stage, and the temperature of the system was elevated to 80 ~C.
Thereafter, to the autoclave was fed hydrogen so that the pressure in the system was 4.0 kg/cm2-G, and was further fed ethylene continuously for 2 hours so that the total pressure was 8.0 kg/cm2-G. The temperature during the polymerization stage was kept at 80 ~C. After the polymerization was completed, an ethylene polymer produced was separated from the hexane solvent and dried.
The results of measurement on the properties of the polymer are set forth in Table 5.
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Table 5 Actlv- MFRBulk Particle Size ity Specif- Distribution Gravity g-PE/g- g/lOmin g/cc >500~m lOO~m SlOO~m cata-lyst 500~m Ex. 6 32,800 2.3 0.34 0.6 98.5 0.9 Comparative Example 3 In a 400 ml four-neck flask, 30 mmol of magnesium chloride anhydride was suspended in 150 ml of n-decane. To the resultant suspension was dropwise added 180 mmol of ethanol over 1 hour with stirring of the suspension, to perform reaction at room temperature for 1 hour. Through 0 the reaction, a white powder was obtained from a swollen magnesium chloride. Then, to the reaction system was dropwise added 84 mmol of diethylaluminum monochloride at room temperature to perform reaction at 30 ~C for 1 hour.
Thereafter, 300 mmol of titanium tetrachloride was added to the reaction system, and the temperature of the system was elevated to 80 ~C to perform reaction for 3 hours while stirring the reaction solution. After the reaction was completed, a solid portion was separated from the solution, and the solid portion was washed with 2 liters of n-decane.
[Polymerization]
2107i~
A 2-liter stainless steel autoclave was thoroughly purged with nitrogen. Then, the autoclave was charged with 1 liter of n-hexane and was heated to 50 ~C. To the autoclave were added 1.0 mmol of trilsobutylaluminum, 0.5 5 mmol of ethylene dlchlorlde and 0.02 mmol (ln terms of T1 atom) of the catalyst obtained in the above, and the autoclave was sealed. Thereafter, into the autoclave was pressed hydrogen until the gauge pressure became 4.5 kg/cm2, and was further pressed ethylene until the gauge pressure became 8 kg/cm2. Then, to the autoclave was contlnuously fed ethylene at 80 ~C for 2 hours so that the total pressure was kept at 8 kg/cm2-G.
The results of measurements on the propertles of the polymer obtained are set forth in Table 6.
Table 6 Activity MFR Bulk Particle Size SpecificDistributionGeometri-Gravity(wt.~) cal 100~m Standard g-PE/g- g/lOming/cc >500~m ~ <100~m Deviation catalyst 500~m Comp. 36,600 3.0 0.31 17.6 65.8 16.5 2.29 Ex. 3
Claims (17)
1. A titanium catalyst component for ethylene polymerization prepared by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, the complex being obtained by contacting:
(a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol (ROH) having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound, at a molar ratio (ROH/Al) of the alcohol to aluminum atoms in the organoaluminum compound (a-2) in the range of from about 0.5 to about 7; with [B] a tetravalent titanium compound, wherein an atomic ratio (Ti/(Mg+Al)) of titanium atoms (Ti) contained in the tetravalent titanium compound [B]
to the total of magnesium atoms (Mg) and aluminum atoms (Al) contained in the solid magnesium complex [A] is in the range of from about 0.005 to 18, and wherein titanium atoms contained in the titanium catalyst component are substantially tetravalent and a molar ratio of the alkoxy group and/or alcohol to titanium is in the range of 0.26 to 6Ø
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, the complex being obtained by contacting:
(a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol (ROH) having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound, at a molar ratio (ROH/Al) of the alcohol to aluminum atoms in the organoaluminum compound (a-2) in the range of from about 0.5 to about 7; with [B] a tetravalent titanium compound, wherein an atomic ratio (Ti/(Mg+Al)) of titanium atoms (Ti) contained in the tetravalent titanium compound [B]
to the total of magnesium atoms (Mg) and aluminum atoms (Al) contained in the solid magnesium complex [A] is in the range of from about 0.005 to 18, and wherein titanium atoms contained in the titanium catalyst component are substantially tetravalent and a molar ratio of the alkoxy group and/or alcohol to titanium is in the range of 0.26 to 6Ø
2. The titanium catalyst component for ethylene polymerization as claimed in claim 1, which is obtained by contacting the solid magnesium aluminum complex [A] with the tetravalent titanium compound [B] in a hydrocarbon solvent.
3. The titanium catalyst component for ethylene polymerization as claimed in claim 1, which is obtained by contacting the solid magnesium aluminum complex [A] with the tetravalent titanium compound [B] at a temperature of 50 to 120°C in a hydrocarbon solvent.
4. A prepolymerized titanium catalyst component for ethylene polymerization obtained by prepolymerizing an olefin to a catalyst comprising:
[I] a titanium catalyst component for ethylene polymerization which is obtained by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, the complex being obtained by contacting:
(a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol (ROH) having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound at a molar ratio (ROH/Al) of the alcohol to aluminum atoms in the organoaluminum compound (a-2) in the range of from about 0.5 to about 7; with [B] a tetravalent titanium compound;
wherein an atomic ratio (Ti/(Mg+Al)) of titanium atoms (Ti) contained in the tetravalent titanium compound [B]
to the total of magnesium atoms (Mg) and aluminum atoms (Al) contained in the solid magnesium complex [A] is in the range of from about 0.005 to 18, and wherein titanium atoms contained in the titanium catalyst component are substantially tetravalent and a molar ratio of alkoxy group and/or alcohol to titanium is in the range of 0.26 to 6.0, and [II] an organoaluminum compound in an amount of 1 to 1000 mols per 1 g-atom of titanium atom contained in the titanium catalyst component [I].
[I] a titanium catalyst component for ethylene polymerization which is obtained by contacting:
[A] a solid magnesium aluminum complex containing magnesium, halogen, aluminum and an alkoxy group and/or alcohol having at least 6 carbon atoms, the complex being obtained by contacting:
(a-1) a magnesium solution formed from a halogen-containing magnesium compound, an alcohol (ROH) having at least 6 carbon atoms and a hydrocarbon solvent, with (a-2) an organoaluminum compound at a molar ratio (ROH/Al) of the alcohol to aluminum atoms in the organoaluminum compound (a-2) in the range of from about 0.5 to about 7; with [B] a tetravalent titanium compound;
wherein an atomic ratio (Ti/(Mg+Al)) of titanium atoms (Ti) contained in the tetravalent titanium compound [B]
to the total of magnesium atoms (Mg) and aluminum atoms (Al) contained in the solid magnesium complex [A] is in the range of from about 0.005 to 18, and wherein titanium atoms contained in the titanium catalyst component are substantially tetravalent and a molar ratio of alkoxy group and/or alcohol to titanium is in the range of 0.26 to 6.0, and [II] an organoaluminum compound in an amount of 1 to 1000 mols per 1 g-atom of titanium atom contained in the titanium catalyst component [I].
5. A catalyst for ethylene polymerization comprising the titanium catalyst component for ethylene polymerization as claimed in claim 1, 2 or 3, and [II] an organoaluminum compound.
6. A catalyst for ethylene polymerization comprising:
the olefin-polymerized titanium catalyst component for ethylene polymerization as claimed in claim 4, and [II] an organoaluminum compound.
the olefin-polymerized titanium catalyst component for ethylene polymerization as claimed in claim 4, and [II] an organoaluminum compound.
7. A process for ethylene polymerization which comprises polymerizing ethylene or copolymerizing ethylene with an .alpha.-olefin having 3 to 20 carbon atoms in the presence 40a of a catalyst for ethylene polymerization comprising:
[I] the titanium catalyst component for ethylene polymerization as claimed in claim 1, 2 or 3, and [II] an organoaluminum compound.
[I] the titanium catalyst component for ethylene polymerization as claimed in claim 1, 2 or 3, and [II] an organoaluminum compound.
8. A process for ethylene polymerization which comprises polymerizing ethylene or copolymerizing ethylene with an .alpha.-olefin having 3 to 20 carbon atoms in the presence of a catalyst for ethylene polymerization comprising:
[I]' the prepolymerized titanium catalyst component for ethylene polymerization as claimed in claim 4, and [II] an organoaluminum compound.
[I]' the prepolymerized titanium catalyst component for ethylene polymerization as claimed in claim 4, and [II] an organoaluminum compound.
9. A method of preparing a particulate titanium catalyst component for ethylene polymerization wherein the catalyst component contains substantially tetravalent titanium atoms, a C6-18 alkoxy group or a C6-18 alcohol at an alkoxy or alcohol/
titanium molar ratio of 0.26 to 6.0, magnesium at a Ti/Mg atomic ratio of 0.01 to 1.5, aluminum at an Al/Mg atomic ratio of 0.1 to 2.0 and halogen, which method comprises:
(I) preparing a solid particulate magnesium aluminum complex containing magnesium, halogen, aluminum and at least one member selected from the group consisting of a C6-18 alkoxy group and a C6-18 alcohol and having an Al/Mg atomic ratio of 0.05 to 1, a content of the alkoxy or alcohol of 0.5 to 15 parts by weight per part of magnesium and an X1/Mg atomic ratio (where X1 is the halogen) of 1 to 3, by contacting at a temperature of -30° to +100°C, (a-1) a magnesium solution formed from a halogen-containing magnesium compound, a C6-18 alcohol and a hydrocarbon or halogenated hydrocarbon solvent, with (a-2) an organoaluminum compound of the formula:
RanAlX3-n (iv) [wherein Ra is a 1-12 hydrocarbon group, X is a halogen or hydrogen atom and n is 1 to 3], and separating the solid particulate magnesium aluminum complex from the resulting mixture, and (II) contacting the solid particulate magnesium aluminum complex with a tetravalent titanium compound of the formula:
Ti(OR2)gX4-g (ii) [wherein R2 is a C1-4 alkoxy group, X is a halogen atom and g is a number of from 0 to 3]
in such an amount that a Ti/(Mg+Al) atomic ratio is in the range of 0.01 to 15, in a hydrocarbon solvent at a temperature of 50° to 130°C, thereby preparing the desired titanium catalyst component for ethylene polymerization.
titanium molar ratio of 0.26 to 6.0, magnesium at a Ti/Mg atomic ratio of 0.01 to 1.5, aluminum at an Al/Mg atomic ratio of 0.1 to 2.0 and halogen, which method comprises:
(I) preparing a solid particulate magnesium aluminum complex containing magnesium, halogen, aluminum and at least one member selected from the group consisting of a C6-18 alkoxy group and a C6-18 alcohol and having an Al/Mg atomic ratio of 0.05 to 1, a content of the alkoxy or alcohol of 0.5 to 15 parts by weight per part of magnesium and an X1/Mg atomic ratio (where X1 is the halogen) of 1 to 3, by contacting at a temperature of -30° to +100°C, (a-1) a magnesium solution formed from a halogen-containing magnesium compound, a C6-18 alcohol and a hydrocarbon or halogenated hydrocarbon solvent, with (a-2) an organoaluminum compound of the formula:
RanAlX3-n (iv) [wherein Ra is a 1-12 hydrocarbon group, X is a halogen or hydrogen atom and n is 1 to 3], and separating the solid particulate magnesium aluminum complex from the resulting mixture, and (II) contacting the solid particulate magnesium aluminum complex with a tetravalent titanium compound of the formula:
Ti(OR2)gX4-g (ii) [wherein R2 is a C1-4 alkoxy group, X is a halogen atom and g is a number of from 0 to 3]
in such an amount that a Ti/(Mg+Al) atomic ratio is in the range of 0.01 to 15, in a hydrocarbon solvent at a temperature of 50° to 130°C, thereby preparing the desired titanium catalyst component for ethylene polymerization.
10. The method according to claim 9, wherein:
the halogen-containing magnesium compound is magnesium chloride, the organoaluminum compound of the formula (iv) is triethylaluminum, and the tetravalent titanium compound of the formula (ii) is titanium tetrachloride.
the halogen-containing magnesium compound is magnesium chloride, the organoaluminum compound of the formula (iv) is triethylaluminum, and the tetravalent titanium compound of the formula (ii) is titanium tetrachloride.
11. The method according to claim 9, wherein:
the halogen-containing magnesium compound is a magnesium halide or an alkoxymagnesium halide;
the organoaluminum compound of the formula (iv) is a trialkylaluminum having 1 to 12 carbon atoms in the alkyl moiety;
the tetravalent titanium compound of the formula (ii) is a titanium tetrahalide, an alkoxytitanium trihalide, a dialkoxytitanium dihalide or a trialkoxytitanium monohalide; and the hydrocarbon or halogenated hydrocarbon solvent used in the preparation of the magnesium solution (a-1) is an aliphatic hydrocarbon solvent.
the halogen-containing magnesium compound is a magnesium halide or an alkoxymagnesium halide;
the organoaluminum compound of the formula (iv) is a trialkylaluminum having 1 to 12 carbon atoms in the alkyl moiety;
the tetravalent titanium compound of the formula (ii) is a titanium tetrahalide, an alkoxytitanium trihalide, a dialkoxytitanium dihalide or a trialkoxytitanium monohalide; and the hydrocarbon or halogenated hydrocarbon solvent used in the preparation of the magnesium solution (a-1) is an aliphatic hydrocarbon solvent.
12. The method according to claim 11, wherein the C6-18 alcohol in the magnesium solution (a-1) is 2-ethylhexanol.
13. A process for ethylene polymerization, which comprises:
polymerizing ethylene alone or in combination with an .alpha.-olefin having 3 to 20 carbon atoms in the presence of a catalyst comprising:
[I] the particulate titanium catalyst component prepared by the method of claim 9, 10, 11 or 12, and [II] an organoaluminum compound of the formula:
RanAlX3-n (iv) [wherein Ra is a C1-12 hydrocarbon group, X is a halogen or hydrogen atom and n is 1 to 3].
polymerizing ethylene alone or in combination with an .alpha.-olefin having 3 to 20 carbon atoms in the presence of a catalyst comprising:
[I] the particulate titanium catalyst component prepared by the method of claim 9, 10, 11 or 12, and [II] an organoaluminum compound of the formula:
RanAlX3-n (iv) [wherein Ra is a C1-12 hydrocarbon group, X is a halogen or hydrogen atom and n is 1 to 3].
14. The titanium catalyst component as claimed in claim 1, 2 or 3, wherein the solid magnesium aluminum complex [A]
has:
an Al/Mg atomic ratio of 0.05 to 1, a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.5 to 15 parts by weight per part by weight of magnesium, and an X1/Mg (wherein M1 is the halogen) atomic ratio of 1 to 3; and wherein the titanium catalyst component has a Ti/Mg atomic ratio of 0.01 to 1.5, an Al/Mg atomic ratio of 0.1 to 2.0, and a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.1 to 15 parts by weight per part by weight of magnesium.
has:
an Al/Mg atomic ratio of 0.05 to 1, a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.5 to 15 parts by weight per part by weight of magnesium, and an X1/Mg (wherein M1 is the halogen) atomic ratio of 1 to 3; and wherein the titanium catalyst component has a Ti/Mg atomic ratio of 0.01 to 1.5, an Al/Mg atomic ratio of 0.1 to 2.0, and a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.1 to 15 parts by weight per part by weight of magnesium.
15. The titanium catalyst component as claimed in claim 4, wherein the solid magnesium aluminum complex [A] has:
an Al/Mg atomic ratio of 0.05 to 1, a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.5 to 15 parts by weight per part by weight of magnesium, and an X1/Mg (wherein M1 is the halogen) atomic ratio of 1 to 3; and wherein the titanium catalyst component has:
a Ti/Mg atomic ratio of 0.01 to 1.5, an Al/Mg atomic ratio of 0.1 to 2.0, and a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.1 to 15 parts by weight per part by weight of magnesium.
an Al/Mg atomic ratio of 0.05 to 1, a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.5 to 15 parts by weight per part by weight of magnesium, and an X1/Mg (wherein M1 is the halogen) atomic ratio of 1 to 3; and wherein the titanium catalyst component has:
a Ti/Mg atomic ratio of 0.01 to 1.5, an Al/Mg atomic ratio of 0.1 to 2.0, and a content of the alkoxy and/or alcohol having at least 6 carbon atoms of 0.1 to 15 parts by weight per part by weight of magnesium.
16. The titanium catalyst component as claimed in claim 14, which is in the form of particles having a particle diameter in the range of from 1 to 200 µm.
17. The titanium catalyst component as claimed in claim 16, wherein the particles has a geometrical standard deviation in the range of from 1.0 to 2Ø
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26606892 | 1992-10-05 | ||
| JP266068/1992 | 1992-10-05 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2107634A1 CA2107634A1 (en) | 1994-04-06 |
| CA2107634C true CA2107634C (en) | 1998-07-28 |
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| Application Number | Title | Priority Date | Filing Date |
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| CA002107634A Expired - Fee Related CA2107634C (en) | 1992-10-05 | 1993-10-04 | Titanium catalyst component for ethylene polymerization, ethylene polymerization catalyst, and process for ethylene polymerization using the same |
Country Status (13)
| Country | Link |
|---|---|
| US (2) | US5468703A (en) |
| EP (1) | EP0591922B1 (en) |
| KR (1) | KR0138631B1 (en) |
| CN (2) | CN1032540C (en) |
| AT (1) | ATE151081T1 (en) |
| CA (1) | CA2107634C (en) |
| CZ (1) | CZ280872B6 (en) |
| DE (1) | DE69309386T2 (en) |
| PL (3) | PL174151B1 (en) |
| RO (1) | RO110505B1 (en) |
| RU (1) | RU2098428C1 (en) |
| SG (1) | SG49178A1 (en) |
| TW (1) | TW302375B (en) |
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| US5571042A (en) * | 1992-10-09 | 1996-11-05 | United States Surgical Corporation | Apparatus for producing hollow ground needles |
| US5770540A (en) * | 1994-06-20 | 1998-06-23 | Borealis Polymers Oy | Procatalyst for ethylene polymer production, method for its preparation and use |
| FI942949A0 (en) * | 1994-06-20 | 1994-06-20 | Borealis Polymers Oy | Prokatalysator Foer production av etenpolymerer och foerfarande Foer framstaellning daerav |
| CN1098867C (en) * | 1998-01-14 | 2003-01-15 | 中国石油化工集团公司 | Slurry process total density polyvinyl high-efficiency catalyst |
| CN1128822C (en) | 1999-02-26 | 2003-11-26 | 中国石油化工集团公司 | Process for preparing catalyst carrier for olefin polymerization |
| CN1150222C (en) * | 1999-06-04 | 2004-05-19 | Lg化学株式会社 | Process for preparing polyolefin polymerization catalysts |
| KR100351386B1 (en) * | 2000-04-24 | 2002-09-05 | 삼성종합화학주식회사 | Catalyst for preparation of ultra high molecular weight polyethylene and preparation method of ultra high molecular weight polyethylene using the same |
| KR100353960B1 (en) * | 2000-05-31 | 2002-09-27 | 삼성종합화학주식회사 | A method for producing ethylene homo- and co-polymer |
| DE10028432A1 (en) * | 2000-06-13 | 2001-12-20 | Basell Polyolefine Gmbh | High-activity olefin polymerization catalysts leaving little or no particulate residue in the polymer comprise calcined hydrotalcite carrier and organo-transition metal compound |
| KR100359932B1 (en) * | 2000-06-15 | 2002-11-07 | 삼성종합화학주식회사 | A catalyst for ethylene homo- and copolymerization |
| CN1131246C (en) * | 2000-12-14 | 2003-12-17 | 中国石油化工股份有限公司 | Catalyst composition for olefine polymerizing or copolymerizing and catalyst and use thereof |
| KR20020096590A (en) * | 2001-06-21 | 2002-12-31 | 삼성종합화학주식회사 | Catalyst for polymerization and copolymerization of ethylene |
| EP1555272B1 (en) * | 2002-10-23 | 2010-12-08 | Mitsui Chemicals, Inc. | Supported olefin polymerisation catalyst |
| EP1572760B1 (en) * | 2002-12-18 | 2016-12-07 | Borealis Technology Oy | Method for the preparation of olefin polymerisation catalyst support and an olefin polymerisation catalyst |
| US7211534B2 (en) * | 2003-02-12 | 2007-05-01 | Formosa Plastics Corporation, U.S.A. | Preparation of a magnesium halide support for olefin polymerization and a catalyst composition using the same |
| KR100702435B1 (en) * | 2004-11-03 | 2007-04-03 | 주식회사 엘지화학 | High activity magnesium supported catalysts and preparation of polyolefin using the same |
| JP4797939B2 (en) * | 2006-11-07 | 2011-10-19 | 富士ゼロックス株式会社 | Discard certificate output device and discard certificate output program |
| CN101274967B (en) * | 2007-03-28 | 2010-05-19 | 中国石油化工股份有限公司 | Catalyst for ethylene polymerization and components thereof |
| JP2013501115A (en) * | 2009-08-06 | 2013-01-10 | バーゼル・ポリオレフィン・イタリア・ソチエタ・ア・レスポンサビリタ・リミタータ | Process for producing ethylene polymers having a narrow molecular weight distribution |
| US8685879B2 (en) * | 2011-04-29 | 2014-04-01 | Basf Corporation | Emulsion process for improved large spherical polypropylene catalysts |
| KR20140136239A (en) * | 2013-05-20 | 2014-11-28 | 삼성토탈 주식회사 | A preparation method of the size-controllable catalyst for ethylene (co)polymerization |
| EP3059261B1 (en) * | 2015-02-23 | 2018-10-03 | Indian Oil Corporation Limited | Process for preparing a catalyst for olefin polymerization and polymerization |
| KR102172190B1 (en) | 2017-12-21 | 2020-10-30 | 인천대학교 산학협력단 | A color electronic textile and preparation method thereof |
| US11124586B1 (en) | 2020-11-09 | 2021-09-21 | Chevron Phillips Chemical Company Lp | Particle size control of metallocene catalyst systems in loop slurry polymerization reactors |
| EP4259670A2 (en) | 2020-12-08 | 2023-10-18 | Chevron Phillips Chemical Company Lp | Particle size control of supported chromium catalysts in loop slurry polymerization reactors |
| CA3232290A1 (en) | 2021-09-13 | 2023-03-16 | Chevron Phillips Chemical Company | Hydrocyclone modification of catalyst system components for use in olefin polymerizations |
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| US4076924A (en) * | 1974-09-03 | 1978-02-28 | Mitsui Petrochemical Industries Ltd. | Process for polymerization or copolymerizing olefins containing at least 3 carbon atoms |
| JPS591407B2 (en) * | 1977-03-04 | 1984-01-12 | 三井化学株式会社 | Method for producing titanium catalyst component |
| US4186107A (en) * | 1978-04-14 | 1980-01-29 | Hercules Incorporated | Solid catalyst component for olefin polymerization |
| JPS5611908A (en) * | 1979-07-11 | 1981-02-05 | Mitsui Petrochem Ind Ltd | Preparation of olefin polymer |
| DE2934689A1 (en) * | 1979-08-28 | 1981-03-12 | Hercules Inc., 19899 Wilmington, Del. | Olefin polymerisation catalyst support - obtd. from a di:alkyl magnesium, alkyl aluminium halide, electron donor and hydrocarbon solvent |
| JPS57159806A (en) * | 1981-03-30 | 1982-10-02 | Mitsui Petrochem Ind Ltd | Polymerization of olefin |
| JPS60195108A (en) * | 1984-03-16 | 1985-10-03 | Mitsui Petrochem Ind Ltd | Titanium-based catalytic component for olefin polymerization |
| EP0494084B1 (en) * | 1988-05-13 | 1997-07-23 | Mitsui Petrochemical Industries, Ltd. | Titanium catalyst components, process for preparing same, catalysts containing same for preparing ethylene polymers and process for preparing said ethylene polymers |
| US5192731A (en) * | 1988-05-13 | 1993-03-09 | Mitsui Petrochemical Industries, Ltd. | Titanium catalyst components, process for preparing same, catalysts containing same for preparing ethylene polymers and process for preparing said ethylene polymers |
| TW198726B (en) * | 1989-12-29 | 1993-01-21 | Mitsui Petroleum Chemicals Ind | |
| US5266544A (en) * | 1989-12-29 | 1993-11-30 | Mitsui Petrochemical Industries, Ltd. | Olefin polymerization catalyst and process for the polymerization of olefins |
| JP3031560B2 (en) * | 1990-08-07 | 2000-04-10 | 三井化学株式会社 | Solid catalyst component, olefin polymerization catalyst containing the solid catalyst component, and method for producing ethylene / α-olefin copolymer using the olefin polymerization catalyst |
| US5180702A (en) * | 1991-12-11 | 1993-01-19 | Phillips Petroleum Company | Metal halide catalyst, method of producing the catalyst, polymerization process employing the catalyst, and polymer produced by the polymerization process |
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- 1993-10-02 TW TW082108092A patent/TW302375B/zh active
- 1993-10-04 CA CA002107634A patent/CA2107634C/en not_active Expired - Fee Related
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- 1993-10-04 RU RU93056587/04A patent/RU2098428C1/en not_active IP Right Cessation
- 1993-10-04 PL PL93321373A patent/PL174154B1/en unknown
- 1993-10-04 PL PL93300577A patent/PL174177B1/en unknown
- 1993-10-04 US US08/130,789 patent/US5468703A/en not_active Expired - Fee Related
- 1993-10-05 AT AT93116074T patent/ATE151081T1/en not_active IP Right Cessation
- 1993-10-05 CN CN93118601A patent/CN1032540C/en not_active Expired - Fee Related
- 1993-10-05 CZ CZ932079A patent/CZ280872B6/en not_active IP Right Cessation
- 1993-10-05 SG SG1996007222A patent/SG49178A1/en unknown
- 1993-10-05 KR KR1019930020473A patent/KR0138631B1/en not_active IP Right Cessation
- 1993-10-05 DE DE69309386T patent/DE69309386T2/en not_active Expired - Fee Related
- 1993-10-05 EP EP93116074A patent/EP0591922B1/en not_active Expired - Lifetime
- 1993-10-05 RO RO93-01311A patent/RO110505B1/en unknown
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Also Published As
| Publication number | Publication date |
|---|---|
| CN1085569A (en) | 1994-04-20 |
| DE69309386D1 (en) | 1997-05-07 |
| PL174177B1 (en) | 1998-06-30 |
| KR0138631B1 (en) | 1998-05-01 |
| CA2107634A1 (en) | 1994-04-06 |
| TW302375B (en) | 1997-04-11 |
| CN1032540C (en) | 1996-08-14 |
| CZ207993A3 (en) | 1994-04-13 |
| DE69309386T2 (en) | 1997-08-07 |
| CN1034944C (en) | 1997-05-21 |
| ATE151081T1 (en) | 1997-04-15 |
| PL174151B1 (en) | 1998-06-30 |
| SG49178A1 (en) | 1998-05-18 |
| EP0591922A1 (en) | 1994-04-13 |
| CZ280872B6 (en) | 1996-04-17 |
| US5623033A (en) | 1997-04-22 |
| EP0591922B1 (en) | 1997-04-02 |
| RU2098428C1 (en) | 1997-12-10 |
| KR940009217A (en) | 1994-05-20 |
| PL174154B1 (en) | 1998-06-30 |
| RO110505B1 (en) | 1996-01-30 |
| US5468703A (en) | 1995-11-21 |
| CN1119651A (en) | 1996-04-03 |
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