Process for producing catalyst for olefin polymerization and...

Details Process for producing catalyst for olefin polymerization and... Process for producing catalyst for olefin polymerization and...

2001-03-16

2003-02-18

Wu, David W. (Department: 1713)

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

Synthetic resins

Polymers from only ethylenic monomers or processes of...

C526S142000, C526S348000, C526S125100, C526S119000, C502S103000, C502S118000, C502S125000, C502S126000

Reexamination Certificate

active

06521725

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a process for producing a catalyst for olefin polymerization, and a process for producing an olefin polymer.
BACKGROUND OF THE INVENTION
An ethylene polymer having a low content of a lower molecular weight component is desired from a viewpoint of properties of films obtained therefrom such as, for example, transparency, impact resistance and blocking resistance.
As a polymerization catalyst having a superior catalyst efficiency, there is known a catalyst comprising (i) a solid catalyst component obtained from a combination of a specific magnesium compound and (ii) a specific titanium compound (cf., for example, JP-B46-34092, JP-B47-41676, JP-B55-23561and JP-B 57-24361). However, an ethylene polymer obtained using such a catalyst is not satisfactory from a viewpoint of blocking resistance.
Further, as a polymerization catalyst for producing a highly crystalline propylene polymer, there is known a catalyst comprising a solid catalyst component obtained using an oxygen-containing electron donor such as an ester as an internal donor (cf., for example, JP-B 52-39431, JP-B 52-36786, JP-B 1-28049 and JP-B 3-43283). However, a copolymer of ethylene and an &agr;-olefin obtained using such a catalyst is also unsatisfactory from a viewpoint of blocking resistance.
Furthermore, JP-A 11-80234 and JP-A 11-322833 disclose a catalyst for ethylene polymerization, which can produce an ethylene polymer having a low content of a lower molecular weight component. However, from a viewpoint of increasing quality of the ethylene polymer, an ethylene polymer having a further low content of a lower molecular weight component is desired.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process for producing a catalyst for olefin polymerization, which can produce an olefin polymer having a low content of a lower molecular weight component.
It is another object of the present invention to provide a process for producing an olefin polymer having a low content of a lower molecular weight component.
The present invention provides a process for producing a catalyst for olefin polymerization, which comprises the step of contacting with one another:
(i) a solid catalyst component containing at least titanium, magnesium and halogen atoms,
(ii) an organoaluminum compound, and
(iii) a compound selected from the group consisting of (a) an oxygen-containing compound having a structure wherein at least two hydrocarbyloxy groups are bound to the same carbon atom, and (b) a cyclic ketone compound.
The present invention also provides a process for producing an olefin polymer, which comprises the steps of:
(1) contacting with one another (i) a solid catalyst component containing at least titanium, magnesium and halogen atoms, (ii) an organoaluminum compound and (iii) a compound selected from the group consisting of (a) an oxygen-containing compound having a structure wherein at least two hydrocarbyloxy groups are bound to the same carbon atom and (b) a cyclic ketone compound to obtain a catalyst for olefin polymerization, and
(2) polymerizing an olefin in the presence of the obtained catalyst for olefin polymerization to obtain an olefin polymer.
DETAILED DESCRIPTION OF THE INVENTION
Oxygen-containing Compound
An “oxygen-containing compound” used in the present invention means a compound having a structure wherein at least two hydrocarbyloxy groups are bound to the same carbon atom. Preferable examples of the hydrocarbyloxy group are alkoxy, aralkyloxy and aryloxy groups. Of these, more preferable is an alkoxy group, and particularly preferable is a methoxy group. A preferable oxygen-containing compound is a compound having a structure wherein two hydrocarbyloxy groups mentioned above are bound to the same carbon atom.
A more preferable oxygen-containing compound is that represented by the following formula,
wherein R
1
and R
2
are independently of each other a hydrogen atom or a hydrocarbon group having 1 to 20 carbon atoms, and R
1
and R
2
may be bound to each other to form a ring, and R
3
and R
4
are independently of each other a hydrocarbon group having 1 to 20 carbon atoms.
As R
1
, R
2
, R
3
and R
4
, alkyl, aryl and aralkyl groups are preferable.
Specific examples of the alkyl group are methyl, ethyl, n-propyl, i-propyl, n-butyl, sec-butyl, tert-butyl, i-butyl, n-pentyl, neopentyl, n-hexyl, n-octyl, n-decyl, n-dodecyl, n-pentadecyl, n-eicoscy, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and cycloheptyl groups. Of these, methyl, ethyl, n-propyl, i- propyl, n-butyl, tert-butyl, i-butyl, cyclopentyl and cyclohexyl groups are preferred.
The above-mentioned alkyl group may be substituted with a halogen atom such as fluorine, chlorine, bromine and iodine atoms. Specific examples of the alkyl group substituted with the halogen atom are fluoromethyl, difluoromethyl, trifluoromethyl, chloromethyl, dichloromethyl, trichloromethyl, bromomethyl, dibromomethyl, tribromomethyl, iodomethyl, diiodomethyl, triiodomethyl, fluoroethyl, difluoroethyl, trifluoroethyl, tetrafluoroethyl, pentafluoroethyl, chloroethyl, dichloroethyl, trichloroethyl, tetrachloroethyl, pentachloroethyl, bromoethyl, dibromoethyl, tribromoethyl, tetrabromoethyl, pentabromoethyl, perfluoropropyl, perfluorobutyl, perfluoropentyl, perfluorohexyl, perfluorooctyl, perfluorododecyl, perfluoropentadecyl, perfluoroeicosyl, perchloropropyl, perchlorobutyl, perchloropentyl, perchlorohexyl, perchlorooctyl, perchlorododecyl, perchloropentadecyl, perchloroeicosyl, perbromopropyl, perbromobutyl, perbromopentyl, perbromohexyl, perbromooctyl, perbromododecyl, perbromopentadecyl and perbromoeicosyl groups.
As the above-mentioned aryl group, preferred is an aryl group having 6 to 20 carbon atoms. Specific examples of the aryl group are phenyl, 2-tolyl, 3-tolyl, 4-tolyl, 2,3-xylyl, 2,4-xylyl, 2,5-xylyl, 2,6-xylyl, 3,4-xylyl, 3,5-xylyl, 2,3,4-trimethylphenyl, 2,3,5-trimethylphenyl, 2,3, 6-trimethylphenyl, 2,4, 6-trimethylphenyl, 3,4,5-trimethylphenyl, 2,3,4,5-tetramethylphenyl, 2,3,4,6-tetramethylphenyl, 2,3,5,6-tetramethylphenyl, pentamethylphenyl, ethylphenyl, n-propylphenyl, i-propylphenyl, n-butylphenyl, sec-butylphenyl, tert-butylphenyl, n-pentylphenyl, neopentylphenyl, n-hexylphenyl, n-octylphenyl, n-decylphenyl, n-dodecylphenyl, n-tetradecylphenyl, naphthyl and anthracenyl groups. Of these, a phenyl group is more preferred.
The aryl group may be substituted partially with a halogen atom such as fluorine, chlorine, bromine and iodine atoms.
As the above-mentioned aralkyl group, preferred is that having 7 to 20 carbon atoms. Specific examples of the aralkyl group are benzyl, (2-methylphenyl)methyl, (3-methylphenyl)methyl, (4-methylphenyl)methyl, (2,3-dimethylphenyl)methyl, (2,4-dimethylphenyl)methyl, (2,5-dimethylphenyl)methyl, (2,6-dimethylphenyl)methyl, (3,4-dimethylphenyl)methyl, (3,5-dimethylphenyl)methyl, (2,3,4-trimethylphenyl)methyl, (2,3,5-trimethylphenyl)methyl, (2,3,6-trimethylphenyl)methyl, (3,4,5-trimethylphenyl)methyl, (2,4,6-trimethylphenyl)methyl, (2,3,4,5-tetramethylphenyl)methyl, (2,3,4,6-tetramethylphenyl)methyl, (2,3,5,6-tetramethylphenyl)methyl, (pentamethylphenyl)methyl, (ethylphenyl)methyl, (n-propylphenyl)methyl, (i-propylphenyl)methyl, (n-butylphenyl)methyl, (sec-butylphenyl)methyl, (tert-butylphenyl)methyl, (n-pentylphenyl)methyl, (neopentylphenyl)methyl, (n-hexylphenyl)methyl, (n-octylphenyl)methyl, (n-decylphenyl)methyl, (n-tetradecylphenyl)methyl, naphtylmethyl and anthracenylmethyl groups. Of these, a benzyl group is more preferred.
The aralkyl group may be substituted partially with a halogen atom such as fluorine, chlorine, bromine and iodine atoms.
As R
1
and R
2
, a hydrogen atom and methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, tert-butyl, cyclopentyl and cyclohexyl groups are preferable.
When R
1
and R
2
are bound to each other to form a ring, a preferred ring structure is a cycloheptane ring structure or a cyclohexane ring structure.
As R
3
and R
4
, methyl and ethyl groups are preferred, and a methyl group is particularly prefe

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