Solid catalyst component and catalyst for olefin...

Details Solid catalyst component and catalyst for olefin... Solid catalyst component and catalyst for olefin...

2003-01-21

2004-12-07

Choi, Ling-Siu (Department: 1713)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

Polymers from only ethylenic monomers or processes of...

C526S124300, C526S124200, C526S348000, C526S090000, C502S125000, C502S087000, C502S151000, C502S156000, C502S103000, C502S115000, C502S127000

Reexamination Certificate

active

06828396

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a solid catalyst component for olefin polymerization, a catalyst for olefin polymerization, a process for producing an olefin polymer and a process for producing a solid catalyst component for olefin polymerization.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,409,875 discloses a solid catalyst component, which is a new olefin polymerization catalyst component, and which is obtained by supporting a magnesium compound and a titanium compound on a carrier of a functional group-carrying polymer. More specifically, the patent discloses a process for producing an ethylene based polymer with use of a catalyst, which catalyst is obtained by a process comprising the following steps (i) to (v):
(i) dissolving an ethylene-unsaturated carboxylic acid copolymer in an organic solvent,
(ii) adding a poor solvent to the resulting solution to precipitate the ethylene-unsaturated carboxylic acid copolymer,
(iii) separating the precipitated copolymer by filtration, drying the separated copolymer, and then pulverizing the dried copolymer,
(iv) contacting the pulverized copolymer, an organomagnesium compound and a transition metal compound with one another to obtain a solid catalyst component, and
(v) contacting the obtained solid catalyst component with an organoaluminum compound to obtain a catalyst.
The patent also discloses that the obtained catalyst can exhibit a high activity in the polymerization of olefin, particularly in the copolymerization of ethylene with an &agr;-olefin.
However, the above-mentioned catalyst is not sufficient from a viewpoint of obtaining an olefin polymer having a low content of lower molecular weight polymers and/or low crystallinity polymers. In addition, the above-mentioned solid catalyst component has a problem such that it contains a lot of fine powders to make its particle size distribution broad, and as a result, the obtained ethylene-&agr;-olefin copolymer is not satisfactory in its powder properties.
SUMMARY OF THE INVENTION
Objects of the present invention are to provide (i) a solid catalyst component for olefin polymerization, (ii) a highly active catalyst for olefin polymerization, (iii) a process for producing an olefin polymer, particularly a copolymer of ethylene with an &agr;-olefin, and (iv) a process for producing a solid catalyst component for olefin polymerization, according to which an olefin polymer having an extremely low content of lower molecular weight polymers and/or low crystallinity polymers, and an olefin polymer having superior powder properties can be obtained.
The present inventors have undertaken extensive studies to achieve the objects. As a result, it has been found that the objects can be achieved by providing (i) a solid catalyst component (A-1) for olefin polymerization, which is obtained from a combination of a carrier (a-1) of carboxyl group-carrying polymer powder having a specific average particle size and a transition metal compound (b) of the number 4 group of metals in the periodic table of elements, and (ii) a solid catalyst component (A-2) for olefin polymerization, which is obtained from a combination of a carboxyl group-carrying polymer carrier (a-2), a transition metal compound (b) of the number 4 group of metals in the periodic table of elements and a phenol compound (c). Thereby, the present invention has been obtained.
The present invention provides a solid catalyst component (A-1) for olefin polymerization, which is obtained by a process comprising the step of contacting:
(a-1) a carrier of carboxyl group-carrying polymer particles having an average particle diameter of from 1 to 300 &mgr;m, and
(b) a transition metal compound of the number 4 group of metals in the periodic table of elements.
The present invention further provides a catalyst for olefin polymerization, which is obtained by a process comprising the step of contacting:
(A-1) the above-mentioned solid catalyst component, and
(B) at least one compound selected from the group consisting of an organoaluminum compound and an organoaluminumoxy compound.
The present invention further provides a process for producing an olefin polymer, which comprises the step of polymerizing an olefin in the presence of the above-mentioned catalyst.
The present invention further provides a process for producing a solid catalyst component (A-1) for olefin polymerization, which comprises the step of contacting:
(a-1) a carrier of carboxyl group-carrying polymer particles having an average particle diameter of from 1 to 300 &mgr;m, and
(b) a transition metal compound of the number 4 group of metals in the periodic table of elements.
The present invention further provides a solid catalyst component (A-2) for olefin polymerization, which is obtained by a process comprising the step of contacting:
(a-2) a carboxyl group-carrying polymer carrier,
(b) a transition metal compound of the number 4 group of metals in the periodic table of elements, and
(c) a phenol compound.
The present invention further provides a catalyst for olefin polymerization, which is obtained by a process comprising the step of contacting:
(A-2) the above-mentioned solid catalyst component, and
(B) at least one compound selected from the group consisting of an organoaluminum compound and an organoaluminumoxy compound.
The present invention further provides a process for producing an olefin polymer, which comprises the step of polymerizing an olefin in the presence of the above-mentioned catalyst.
The present invention further provides a process for producing a solid catalyst component (A-1) for olefin polymerization, which comprises the step of contacting:
(a-2) a carboxyl group-carrying polymer carrier,
(b) a transition metal compound of the number 4 group of metals in the periodic table of elements, and
(c) a phenol compound.


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