Process for producing solid product, solid catalyst...

Details Process for producing solid product, solid catalyst... Process for producing solid product, solid catalyst...

2001-12-26

2004-01-27

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...

C526S348000, C526S124300, C526S158000, C526S125100, C526S128000, C502S103000, C502S115000, C502S116000, C502S126000, C502S127000, C502S128000

Reexamination Certificate

active

06683139

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to (i) a process for producing a solid product, (ii) a process for producing a solid catalyst component for olefin polymerization using the solid product, (iii) a process for producing a catalyst for olefin polymerization using the solid catalyst component, and (iv) a process for producing an olefin polymer using the solid catalyst.
BACKGROUND OF THE INVENTION
As a process for improving physical properties such as rigidity and heat resistance of an olefin polymer, there is known a process, which comprises a step of melt-kneading the olefin polymer with an inorganic substance, thereby granulating the inorganic substance into fine particles and dispersing the fine particles in the olefin polymer.
However, the above-mentioned process has a problem that the inorganic substance cannot be fully granulated, so that dispersion of the inorganic substance in the olefin polymer is not sufficient.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a process for producing an olefin polymer in which a finely granulated inorganic substance is satisfactorily dispersed.
Another object of the present invention is to provide a process for producing a catalyst, which catalyst is suitable for the above-mentioned process for producing an olefin polymer.
A further object of the present invention is to provide a process for producing a solid catalyst component, which component is suitable for the above-mentioned process for producing a catalyst for olefin polymerization.
A still further object of the present invention is to provide a process for producing a solid product containing a finely granulated inorganic substance, which solid product is suitable for the above-mentioned process for producing a solid catalyst component.
The present invention provides a process for producing a solid product (A), which comprises the step of reducing a titanium compound represented by the following formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond and an inorganic fine particle,
wherein “a” is a number of 1 to 20, R
2
is a hydrocarbon group having 1 to 20 carbon atoms, and X
2
is a halogen atom or a hydrocarbyloxy group having 1 to 20 carbon atoms, and all of X
2
may be the same or different from one another.
The present invention also provides a process for producing a solid product (B), which comprises the step of reducing a titanium compound represented by the above-mentioned formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond, an ester compound and an inorganic fine particle.
The present invention further provides a process for producing a solid catalyst component (A) for olefin polymerization, which comprises the step of contacting:
(i) the solid product (A) obtained by the above-mentioned process,
(ii) a halogenation ability-carrying halogeno compound (namely, a halogeno compound which has an ability to halogenate), and
(iii) an inner electron donor compound.
The present invention still further provides a process for producing a solid catalyst component (B) for olefin polymerization, which comprises the step of contacting:
(i) the solid product (B) obtained by the above-mentioned process,
(ii) a halogenation ability-carrying halogeno compound, and
(iii) an inner electron donor compound.
The present invention additionally provides a process for producing a catalyst (A) for olefin polymerization, which comprises the step of contacting:
(a) a solid catalyst component (A) obtained by the above-mentioned process,
(b) an organoaluminum compound, and
(c) an outer electron donor compound.
The present invention also additionally provides a process for producing a catalyst (B) for olefin polymerization, which comprises the step of contacting:
(a) a solid catalyst component (B) obtained by the above-mentioned process,
(b) an organoaluminum compound, and
(c) an outer electron donor compound.
The present invention further additionally provides a process for producing an olefin polymer, which comprises the step of polymerizing an olefin in the presence of a catalyst (A) obtained by the above-mentioned process.
The present invention still further additionally provides a process for producing an olefin polymer, which comprises the step of polymerizing an olefin in the presence of a catalyst (B) obtained by the above-mentioned process.
DETAILED DESCRIPTION OF THE INVENTION
Preferable examples of the organosilicon compound having an Si—O bond used in the present invention are those represented by any one of the following formulas (1) to (3).
Si(OR
10
)
t
R
11
4−t
  (1)
R
12
(R
13
2
SiO)
u
SiR
14
3
  (2)
(R
15
2
SiO)
v
  (3)
wherein R
10
is a hydrocarbon group having 1 to 20 carbon atoms; R
11
, R
12
, R
13
, R
14
and R
15
are independently of one another a hydrocarbon group having 1 to 20 carbon atoms or a hydrogen atom; “t” is a number satisfying 0<t≦4; “u” is an integer of from 1 to 1000: and “v” is an integer of from 2 to 1000.
Examples of the organosilicon compound are tetramethoxysilane, dimethyldimethoxysilane, tetraethoxysilane, triethoxyethylsilane, diethoxydiethylsilane, ethoxytriethylsilane, tetra-i-propoxysilane, di-i-propoxy-di-i-propylsilane, tetrapropoxysilane, dipropoxydipropylsilane, tetrabutoxysilane, dibutoxydibutylsilane, dicyclopentoxydiethylsilane, diethoxydiphenylsilane, cyclohexyloxytrimethylsilane, phenoxytrimethylsilane, tetraphenoxysilane, triethoxyphenylsilane, hexamethyldisiloxane, hexaethyldisiloxane, hexapropyldisiloxane, octaethyltrisiloxane, dimethyl polysiloxane, diphenyl polysiloxane, methylhydro polysiloxane and phenylhydro polysiloxane.
Among the organosilicon compounds represented by the above formulas (1) to (3), more preferable are those represented by the formula (1), wherein satisfying 1≦t≦4 is preferable. Of these, tetraalkoxysilane compounds of t=4 are particularly preferred, and the most preferred is tetraethoxysilane.
Examples of R
2
in the above formula [I] representing the titanium compound used in the present invention are alkyl groups such as methyl, ethyl, propyl, i-propyl, butyl, i-butyl, amyl, i-amyl, hexyl, heptyl, octyl, decyl and dodecyl groups; aryl groups such as phenyl, cresyl, xylyl and naphthyl groups; cycloalkyl groups such as cyclohexyl and cyclopentyl groups; allyl groups such as a propenyl group; and aralkyl groups such as a benzyl group. Among these, alkyl groups having 2 to 18 carbon atoms and aryl groups having 6 to 18 carbon atoms are preferred, and linear alkyl groups having 2 to 18 carbon atoms are particularly preferred.
As the halogen atom represented by X
2
in the above formula [I], a chlorine atom, a bromine atom and an iodine atom are exemplified. Of these, a chlorine atom is particularly preferred. As hydrocarbon groups in the oxyhydrocarbon groups having 1 to 20 carbon atoms represented by X
2
, the same hydrocarbon groups as the above-mentioned R
2
can be exemplified. Of these, alkoxy groups having linear alkyl groups of 2 to 18 carbon atoms are particularly preferable as X
2
.
Preferable “a” in the above formula (I) is a number satisfying 1≦a≦5.
Examples of the titanium compound having “a” of not less than 2 are tetra-i-propyl polytitanate (a mixture of compounds of “a”=2~10), tetra-n-butylpolytitanate (a mixture of compounds of “a”=2~10), tetra-n-hexyl polytitanate (a mixture of compounds of “a”=2~10), tetra-n-octyl polytitanate (a mixture of compounds of “a”=2~10) and a condensate of a tetraalkoxytitanium obtained by reacting a tetralkoxytitanium with a small amount of water.
More preferable titanium compounds are those represented by the following formula (4).
 Ti(OR
2
)
q
X
3
4−q
  (4)
wherein R
2
is a hydrocarbon group having 1 to 20 carbon atoms, X
3
is a halogen atom, and q is a number satisfying 0<q≦4, preferably 2≦q≦4, and particularly preferably q=4.
Examples of the

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