Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Plural component system comprising a - group i to iv metal...
Patent
1988-01-05
1989-05-09
Garvin, Patrick P.
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Plural component system comprising a - group i to iv metal...
502107, 502125, 502127, B01J 3700, C08F 400, C08F 460, C08F 464
Patent
active
048290378
DESCRIPTION:
BRIEF SUMMARY
DESCRIPTION
1. Technical Field
This invention relates to a catalyst for the polymerization of olefins which exhibits a high catalytic activity and is capable of producing a highly stereoregular olefin polymer having regular particle size distribution in a high yield.
2. Background Art
A catalyst for the polymerization of olefins formed by combining a solid titanium halide as a catalyst component with an organoaluminum compound is well known and extensively used in the art. However, in the polymerization of olefins by use of the conventional catalyst, the yield of polymer per unit weight of the catalyst component or of titanium moiety in the catalyst component (hereinafter referred to as a polymerization activity per unit weight of the catalyst component or of titanium moiety in the catalyst component) is so low that the so-called deashing process for removing catalyst residues from the produced polymer is indispensable. In the deashing process, alcohols or chelating agents are used in large amounts, so that the deashing process needs an apparatus for recovery or reprocess thereof, and consequently has many problems accompanying therewith relative to resources, energy and the like. Thus, the deashing process raises great problems to be solved urgently in the art. A number of studies and suggestions have been made for enhancing the polymerization activity per unit weight of catalyst component or of titanium moiety in the catalyst component, so that the complicated deashing process may be dispensed with.
Especially as a recent tendency, a large number of suggestions have been made such that the polymerization activity per unit weight of titanium in the catalyst component is remarkably enhanced in the polymerization of olefins with a catalyst component prepared by supporting a transition-metal compound as an active ingredient such as a titanium halide on such a carrier material as magnesium chloride.
However, the improved process employing magnesium chloride as a carrier has such drawbacks that chlorine moiety contained in the magnesium chloride predominantly used as the carrier as well as a halogen atom contained in the titanium halide gives bad influence on the resultant polymer, resulting in leaving problems to be solved such as requirements for such a high activity as to be substantially free from the adverse effect due to the chlorine moiety, or as requirements for controlling a concentration of the magnesium chloride itself at a sufficiently low level.
The present inventors proposed a process for preparing a catalyst component for the polymerization of olefins in Japanese Patent application No. 200454/1982 for an object of reducing a chlorine content in the produced polymer with high polymerization activity and high yield of stereoregular polymer, attaining the aforementioned object. Further, it is essential for a catalyst formed by combining a catalyst component using magnesium chloride as a carrier with an organoaluminum compound to carry out on an industrial scale the polymerization of olefins, especially stereoregular polymerization of propylene, 1-butene, and the like in the presence of an electron donor compound such as aromatic carboxylic acid esters in the polymerization system. However, the aforementioned aromatic carboxylic acid ester imparts a peculiar estereal odor to the produced polymer, raising a serious problem of deodorizing therefrom in the art.
It was substantially impossible for the so-called highly active supported catalyst formed by use of a catalyst component employing the aforementioned magnesium chloride as a carrier to be of practical use, because use of the supported catalyst results in abrupt deactivation thereof in spite of high activity thereof in the beginning of polymerization, and results in raising problems in process operations, particularly in the case where a prolonged polymerization time is required as in block copolymerization and the like. In order to solve the aforementioned problems, Japanese Patent laid-open publication No. 94590/1979 discloses a catalyst for t
REFERENCES:
patent: 4485187 (1984-11-01), Nomura et al.
patent: 4547476 (1985-10-01), Terano et al.
patent: 4686200 (1987-08-01), Terano et al.
Kimura Kohei
Soga Hirokazu
Terano Minoru
Garvin Patrick P.
Irzinski E. D.
Toho Titanium Co., Ltd.
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