Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Plural component system comprising a - group i to iv metal...
Patent
1992-06-16
1995-05-09
Sneed, Helen M. S.
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Plural component system comprising a - group i to iv metal...
502104, 502116, 502117, 502118, 502119, 502120, 502124, B01J 3100
Patent
active
054139791
DESCRIPTION:
BRIEF SUMMARY
The invention relates to a method for the preparation of a solid procatalyst composition for a catalyst system intended for the polymerization of olefins, method in which support material is impregnated with magnesium halide and a monocarboxylic acid alkyl ester which dissolves the halide, and the impregnated support material is reacted with an organometallic compound or a silicon compound and treated with a transition metal compound.
For the polymerization of olefins there is commonly used the so-called Ziegler-Natta catalyst system, which comprises a so-called procatalyst and a cocatalyst. The procatalyst is based on a compound of a transition metal belonging to any of Groups IVB-VIII of the periodic table of the elements, and the cocatalyst is based on an organometallic compound of a metal belonging to any of Groups IA-IIIA of the periodic table of the elements.
In the preparation of heterogeneous polymerization catalysts it is conventional to use as a component improving the polymerization activity of procatalysts a support compound on which the transition metal compound is deposited. Silica, aluminum oxide, magnesium oxide, titanium oxide, carbon in various forms, and various types of polymers are common support compounds. Compounds which have proven to be important support compounds include magnesium compounds such as alkoxides, hydroxides, hydroxy halides and halides, of which the last-mentioned, specifically magnesium dichloride, have recently become the most important support components for procatalyst compositions.
Since magnesium halides in their basic crystal form are not very effectively activated by a transition metal compound, their crystal structure has to be deformed. Conventionally this is done by milling, for example in a ball mill, the result obtained being typically a finely-divided powder with a large specific surface area and with highly deformed crystal lattices of the particles. When such a powder is activated to form a procatalyst composition by deposition with a transition metal compound, and is thereafter reduced with an organometallic compound serving as the cocatalyst, a highly active polymerization catalyst is obtained.
The conventional method of milling magnesium halide has, however, the disadvantage that it consumes a very large amount of energy, causes wear and corrosion of the apparatus, and is usable for the preparation of a catalyst only by a cumbersome batch process.
A more novel and more efficient method of decreasing the crystallinity of magnesium halides, and thereby of increasing their ability to become activated by transition metal compounds, is chemical modification. Therein the magnesium halide, an electron donor, and a transition metal compound are caused, often in a solution, to react with each other to form easily separable procatalyst compositions. U.S. Pat. Nos. 4,124,532 and 4,174,429 describe the preparation of such catalytically active complexes by reacting at a suitable ratio a magnesium halide and a transition metal compound in an electron donor solvent. The completed complex can be separated by evaporation crystallization of the said solvent or by doping the complex with a solvent in which it does not dissolve. Since such complex compounds are produced as a result of spontaneous crystallization, their crystal structure is very regular and their activity respectively quite limited. U.S. Pat. Nos. 4,302,566 and EP Application 6110 describe a precursor comprising a magnesium halide, a transition metal compound, and an electron donor. The precursor is formed by precipitation out of an electron donor solution, whereafter it is separated and mixed with an aluminum alkyl which activates it and with a separate inert support material.
Even in these methods there is not formed a substantially amorphous procatalyst composition, since the said precursor crystallizes spontaneously in the preparation process and will thereafter not substantially change its morphology.
Other patents describe Ziegler-Natta procatalysts on a silica support or a magnesium silicate supp
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Gustafsson Bill
Kostiainen Arja
Sormunen Pekka
Borealis Holding A/S
Irzinski E. D.
Sneed Helen M. S.
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