IMPROVED PROCESS FOR THE POLYMERIZATION OR COPOLYMERIZATION OF BUTADIENE

Abstract: This invention concerns the production of 1,4-cis polybutadiene or copolymers of butadiene with other related diolefins through the catalytic polymerization or copolymerization of butadiene monomer by a continuous or discontinuous process carried out in the absence or substantial absence of solvents or diluents, operating in two successive phases (the first at a T<30°C and the second at a T = or>30°C) by control of the molecular weights.

Description: This invention concerns the production of 1,4-cis polybutadiene through the catalytic polymerization of butadiene monomer by a continuous process carried out in the absence or substantial absence of solvents or diluents, operating in two successive phases (the first at a T<30°C and the second at a T = of from 50°C to less than 90°C) in one or more polymerization reactors in which the heat of reaction is dissipated by evaporation of the monomer. Various catalytic processes for the polymerization of butadiene, apt to produce polybutadiene with a high 1,4-cis content and particularly suited for the manufacture of tires and other elastomer articles, are known in the art. The catalysts generally used for the purpose derive from the combination of transition metal compounds such as titanium, cobalt, nickel, uranium and rare earth metals, with alkyls and/or hydride derivatives of metals of groups IA, IIA and IIIA of the periodic system, such as for example described in the U.S. Patents 3, 118,864, 3,178,402, 3,794,604 and 4,242,232 and in the Belgian Patents 559,676, 573,680 and 791,709. According to the processes known in the art, the polymerization of butadiene is most often carried out in hydrocarbon solution for the purpose of controlling the temperature of polymerization and thus obtaining soluble linear polymers, free or essentially free of gel and with a controlled molecular weight. The production of 1,4-cis polybutadiene through mass polymerization, on the other hand has not found significant development in industrial practice, notwithstanding the evident advantages offered by a process carried out in the absence or substantial absence of solvents or diluents, in comparison with a conventional process in solution. The reasons for this lack of success are to be found principally: A) in the lack of suitably defined catalytic systems which satisfy the peculiarities required for mass polymerization and more particularly: which, in the presence of an excess of monomer, do not give rise to "transfer" reactions, this being responsible for obtaining low molecular weight polymers, rarely usable in applications; which do not cause secondary cross-linking reactions, cyclization and/or ramification in the polymer, this being responsible for the formation of substantial quantities of gel, with greatly negative effects for the characteristics required for the finished product; which present sufficiently high activity, so that the finished polymer contains a low level of catalytic residues, in order to obviate a washing treatment; which retain a high activity and selectivity in the high temperature conditions required to operate in a highly viscous system and with satisfactory kinetics; B) in the technical, rheological and heat exchange difficulties relative to the treatment of highly viscous polymer masses. An example of a process for the mass polymerization of butadiene in order to produce 1,4-cis polybutadiene is described in the U.S. Patent 3,770,710. The U.S. Patent 3,770,710 in fact concerns a process for the mass polymerization of diolefin monomers with lithium catalysts carried out in a conventional reactor, in two phases at different temperatures, and evaporating the monomer in order to control the temperature. The operation in controlled phases derives exclusively from the need to prevent, or at least minimize, the phenomena relative to the foam and to complete the polymerization at a higher temperature. EP-A-0 127 236 discloses and claims a process for preparing cis-1,4-polybutadiene by catalytic polymerization of butadiene, characterized in that: a catalytic mixture is prepared by contacting, in an inert hydrocarbon medium: a) at least one neodymium compound selected from among neodymium oxide. alcoholates, phenates and carboxylates; b) at least one organic compound containing hydroxyl(alcoholic or phenolic) or carboxylic groups selected from among alcohols, phenols, and carboxylic acids, water being optionally added; c) at least one halogenated compound selected from among secondary or tertiary alkyl halides, aryl or alkylaryl halides, organic acid halides, metal or organometallic halides, hydrogen halide acids and halogens, and d) at least one aluminium organometal compounds or relative hydride derivatives thereof, the quantities of the compounds a) and b) being such that the ratio of the hydroxyl groups (those of water included) and/or carboxyl groups to the neodymium atoms is between 2:1 and 100:1, said components being contacted so as to obtain a catalytic mixture wherein the Al/Nd atomic ratio is between 20:1 and 200:1 and the halogen/Nd atomic ratio is between 0,2:1 and 3:1, the solvents or diluents, if used being not more than 2% of the weight of the butadiene monomer; continuously feeding said catalytic mixture and liquid butadiene monomer, optionally premixed, in the proportion of between 4.10⁴ and 4.10⁵ gram.mol of butadiene per gram.atom of Nd. to one end of an elongated polymerisation reactor in which the mixture is polymerised under plug-flow conditions, while maintaining an inlet temperature of not less than 30°C and an outlet temperature of not greater than 130°C and controlling the temperature within said range by partial evaporation of butadiene monomer from the liquid polymerisation phase, until a mixture is obtained having a polymer content of between about 25% and about 70% by weight, this being discharged from the other end of the reactor; the cis-1,4-polybutadiene is separated and recovered from said discharged mixture. From the discharged mixture, the cis-1,4-polybutadiene is recovered as a finished product, evaporating the unreacted butadiene and the solvent, if any is used as a medium for the catalyst, from the polymer mass which contains a "short-stopper" for the catalyst and stabilizers intended to prevent thermo-oxidative degradation. This evaporation takes place in a solvent-removing extruder. However, when operating continuously with such a process at an inlet temperature not below 30°C, cis-1,4-polybutadiene is generally obtained, the Mooney viscosity (ML) of which is not constant, due to insufficient homogeneization of the system composed of the catalyst, the monomer and the polymer. The product thus obtained does not comply with certain technical specifications, and the results are hardly reproducible on a larger scale. According to the invention, there is now provided: A solvent-less 2-stage process for preparing a constant-viscosity cis-1 ,4-polybutadiene by catalytic polymerization of butadiene, comprising the steps of: preparing a catalytic mixture by contacting, in an inert hydrocarbon medium: a) at least one neodymium compound selected from among neodymium oxide, alkoxides, phenates and carboxylates; b) at least one organic compound containing hydroxyl (alcoholic or phenolic) or carboxylic groups, selected from among alcohols, phenols, and carboxylic acids, water being optionally added; c)at least one halogenated compound selected from among secondary or tertiary alkyl halides, aryl or alkylaryl halides, organic acid halides, metal or organometallic halides, hydrogen halide acids and halogens, and d) at least one aluminium organometal compound or a hydride derivative thereof, the quantities of the compounds a) and b) being such that the ratio of the hydroxyl groups (those of water included) and/or carboxyl groups to the neodymium atoms is between 2:1 and 80:1, said components being contacted so as to obtain a catalytic mixture wherein the A1/Nd atomic ratio is between 20:1 and 80:1 and the halogen/Nd atomic ratio is between 0,2:1 and 3:1; continuously or discontinuously feeding said catalytic mixture and liquid butadiene monomer, optionally premixed, in the proportion of between 4.10⁴ and 4.10⁵ gram. mol of butadiene per gram.atom of Nd and carrying out the polymerization until obtaining a mixture having a polymer content of between about 25% and about 70% by weight, characterized in that the polymerization is carried out in a first stage at a temperature lower than 30°C and is discontinued as soon as a 5% to 20% conversion of butadiene into cis-1 ,4-polybutadiene is attained, and in a second stage is at a temperature of from 50°C to less than 90°C, and discharging said polymeric mixture, wherefrom the constant-viscosity cis-1,4-polybutadiene is separated and recovered. Therefore it was surprising to find that, while the mass polymerization of butadiene carried out at 30°C and above takes place in heterogeneous phase due to the insolubility of the polymer in the monomer, the same reaction carried out at a lower temperature takes place in a single phase homogeneous system. In these conditions, with the polymer dissolved and the catalyst not segregated, the molecular weights are rigorously controlled by the physical and chemical parameters of the reaction and the resulting product is homogeneous throughout. However, since there is little need to carry out the mass polymerization to high conversions in an ever more viscous phase, due to the high energy consumption required, and it is useful to act with relatively higher kinetics, it has been found particularly advantageous to operate in two successive phases: the first at T<30°C (preferably within the interval between 0 and 30°C) and the second at T = 50°C to less than 90°C). The first low temperature phase, e.g. at 20°C, can be carried out to any desired conversion, but it is clearly preferable to avoid the high viscosities resulting from high conversions, as well as the limited homogeneizing effect of an early separation of the single phase in two phases. In fact, with increased temperature, and as soon as it exceeds the threshold of 30-35°C, there occurs a separation of the polymer, first dissolved, in a solid phase separate from the liquid phase consisting of the excess monomer. It is preferable that this takes place when 5 to 20% of the butadiene is already polymerized. The advantage provided by the new procedure, demonstrated by the homogeneous ML values measured at various points of the reactor operating at higher temperature, is conceivably related to the fact that upon separation between swollen polymer and monomer, rather small solid particles are formed which are easily removed and transported by the agitator and agglomerate in larger forms only as the polymerization progresses. However, this agglomerate has a quite different consistency than that occurring in the absence of separation (operating at a single temperature in excess of 30°C); it more pasty and opportunely more compatible with the liquid phase, and is therefore more readily homogeneized by the mechanical action of the agitator. A second valuable advantage of two-step polymerization at two different temperatures comes from the fact that, with equal proportions and equal conversion, a lower average molecular weight (ML) is obtained than in the case of reactions carried out entirely at the temperature of the second step. This advantage is measurable in terms of Al-alkyl saved, this being the transfer agent utilized to maintain the molecular weights. The quantity saved is in relation to the ML value (Mooney viscosity values (1+4, 100° : ML)) and in the conversion of the first step it is of significant economic extent, as the ML decrease is of at least 10 points (generally approximately 30 ML points) and the Al-alkyl represents the highest cost item among the catalytic components. More particularly, according to this invention; a catalytic mixture is prepared by placing in contact, in an inert hydrocarbon medium: a) at least one neodymium compound chosen from among neodymium oxides, alcoholates, phenates and carboxyls, or mixtures of these with other rare earth elements; b) at least one organic compound containing hydroxyl groups deriving from alcohols or phenols, or carboxyl groups, with the possible addition of water; c) at least one halogen compound, chosen from among the secondary or tertiary alkyl, aryl or alkylaryl halides, halides of organic acids, metallic or organometallic hydrogen halide acids and halogens; d) at least one organometallic compound of aluminum or relative hydride derivatives; the quantity of compounds a) and b) being such as to respect a ratio of 2/1 to 80/1 between the hydroxy and/or carboxy groups and the neodymium atoms and to hold these components in contact in order to obtain a catalytic mixture in which the aluminum/neodymium atomic ratios of 20/1 to 80/1 and the halogen/neodymium ratios of 0.2/1 to 3/1 are respected; this catalytic mixture and the liquid butadiene monomer, possibly pre-mixed, are fed in quantities of 10⁴ to 4.10⁵ g.mols of butadiene for each g.atom of neodymium, or discontinuously into a polymerization reactor under agitation, or continuously in two reactors in series the first of which is homogeneous or to one end of an elongated reactor in which takes place the polymerization of the mixture which runs by piston ("plug-flow"), operating initially in all cases at T<30°C (first stage) and subsequently at a T greater than 50°C and less than 90°C (second stage), the temperature being controlled by partial evaporation of the butadiene monomer from the liquid phase of polymerization at constant pressure until a mixture with a polymer content of approximately 25 to approximately 70% by weight is obtained. the 1,4-cis polybutadiene is separated and recovered from this mixture discharged from the reactor. The vehicle utilized for the catalyst according to this invention can be composed of inert (non reacting) hydrocarbons, with a low or relatively low boiling point, alicyclic, cyclic or branched, such as butane, pentane, hexane, cyclohexane and heptane, or mixtures thereof. These hydrocarbons, introduced with the catalyst in small quantity even decidedly less than 5% by weight of the polymer produced, are separated from the polybutadiene upon completion of the two phases of polymerization. According to another form of execution, the vehicle for the catalyst is composed of hydrocarbons, or hydrocarbon mixtures, or high molecular weight such as oil of paraffin, or hydrocarbon oils required for formulations of oil-extended polybutadienes. These hydrocarbons do not require separation and remain incorporated in the polybutadiene. It has been found in particular that when the content of oil of paraffin and the like is less than approximately 5% by weight of the polymer, the polymer's characteristics are not modified appreciably. The neodymium compounds used in the preparation of the catalyst are chosen from among neodymium oxide (Nd₂O₃), neodymium alcoholates of aliphatic and cycloaliphatic alcohols, neodymium phenates and carboxylates of aliphatic, cycloaliphatic and aromatic organic acids. Of all the above, preference is given to neodymium oxide, neodymium tributylate, neodymium trinaphtenates and neodymium tri(2 ethyl-hexanaoate). The organic compounds containing hydroxyl groups (alcoholic or phenolic) or carboxyl groups are chosen from among aliphatic and cycloaliphatic alcohols, phenols and substituted phenols, aliphatic, cycloaliphatic and aromatic acids. Of all these preference is given to butyl alcohol, 2-ethylhexanoic acid, naphtenic acids and versatic acids. These compounds can be utilized in the free form, or partially or totally in the combined form with neodymium (neodymium alcoholates, phenates and carboxylates), as long as a ratio of the order of 2/1 to 80/1 between the hydroxyl groups (including those of the water) and the free and/or combined carboxyl groups and the neodymium atoms is respected. It has been found that the addition of limited quantities of water, as a hydroxyl contributing compound, is desirable in that it improves the activity of the catalyst. More particularly, this effect of the waters manifests itself when ratios in the range of 1/1 to 5/1 are maintained between the aluminum atoms of the organometallic aluminum compound or relative hydric compound and the mols of added water, the preferred values being approximately 2/1. The halogen contributing compounds utilized in the preparation of the catalyst are preferably chosen from among hydrochloric acid, diethylaluminum chloride, ethylaluminum dichloride,aluminum trichloride, terbutylchloride, benzyl chloride and benzoyl chloride. In particular, hydrochloric acid can be introduced in the form of aqueous hydrochloric acid in order to furnish the desired quantity of water. The organometallic compounds of aluminum and relative hydric derivatives are the aluminum trialkyls and the hydrides of aluminum alkyl. Preference is given to triethylaluminum, triisobutylaluminum and diisobutylaluminum monohydride. The quantities of the various components of the catalyst are metered so as to maintain a ratio of gram atoms of aluminum/neodymium of 20/1 to 80/1 and a ratio of gram atoms of halogen/neodymium of 0.2/1 to 3/1. In the preferred embodiment the values of the above mentioned ratios are of the order of 3/1 - 30/1 for the hydroxyl groups (including those of the water) and/or carboxyl/neodymium atoms, of the order of 25/1 -50/1 for the aluminum atoms/neodymium atoms, and of the order of 1/1 -2/1 for the halogen atoms/neodymium atoms. According to the process of this invention the catalytic mixture is prepared by placing the above indicated catalytic components in contact in the hydrocarbon vehicle, operating at ambient or above ambient temperatures. The order and the method of addition of the catalytic components are not particularly critical; however, according to one form of execution, they are placed in contact on the hydrocarbon vehicle in the order indicated and at ambient temperature or lower (20-25°C): neodymium alcoholate, phenate and/or carboxylate; organometallic aluminum compound and/or relative hydride derivative; halogenated compound; hydroxyl and/or carboxyl compound and/or water. According to another form of execution they are placed in contact in the hydrocarbon vehicle in the order indicated and at a temperature of 50-80°C: neodymium oxide; hydroxyl and/or carboxyl organic compound; halogenated compound; water. The mixture is then cooled to ambient temperature or lower (20-25°C) and the following is added: organometallic aluminum compound or relative hydride derivative. Operating as indicated above a catalytic solution, or else a catalytic mixture in which the catalyst is mostly dissolved in the relative hydrocarbon vehicle, is obtained. The catalytic mixture thus prepared is mixed with liquid butadiene monomer, in such quantity as to respect a ratio of 10⁴ to 4.10⁵ between g.mols of butadiene and the g.atoms of neodymium. Mixing can be carried out in any apparatus ensuring good homogeneization, for example a vessel under agitation acting as a batch polymerization reactor or first reactor in a continuous process. Mixing is done at a suitably chosen temperature, but below 30°C. In the case of batch polymerization this temperature is subsequently increased (50°C < T < 90°C) for the second step of the reaction, with resulting separation in a solid polymeric phase and a liquid monomeric phase. The heat of reaction is dissipated by evaporation and recycling of the butadiene and constant pressure. According to another form of execution in continuous, a stream of the catalytic mixture and a stream of liquid butadiene are introduced independently in a first polymerization reactor, adhering to the ratios indicated above. While maintaining a temperature below 30°C in the first step, 5 to 20% of the butadiene is polymerized, obtaining a viscous liquid which is introduced at the end of an elongated polymerization reactor operating above 30°C and in which the reaction mass can flow by piston, or substantially by piston. For example, the extruders in which the polymerization mass is driven by self-cleaning single or double screw agitators are suitable for the purpose. The polymerization in this second step is carried out between an inlet temperature > 50°C and an outlet temperature less than 90°C. In both polymerization steps, temperature control is achieved by partially evaporating the butadiene monomer at constant pressure; after condensation, it can be recycled to the reaction with no need for purification. The pressures at which polymerization is carried out are those which ensure the presence of butadiene monomer in liquid phase. For the temperature interval indicated above, these pressure values are suitably chosen as follows: less than 0.35 MPa (3.5 bars) for the first step, and from 0.35 MPa (3.5 bars) to 1.8 MPa (18 bars) absolute for the the next. Operating within the range of general conditions outlined above, a mixture is discharged from the reactor having a polymer content of approximately 25 to approximately 70% by weight with residence times of 10 to 120 minutes. In the preferred operating conditions the overall residence times for the two steps are of the order of 20-60 minutes. For reasons of economy, it is convenient to operate with relatively high rates of conversion of butadiene to the relative polymer, discharging from the reactor mixtures with a polymer content of 60-70% by weight. According to an embodiment of this invention, the mixture coming from the polymerization reactor is sent to a mixing apparatus in which are fed the polymerization arresting agents ("short-stopper") and the stabilizers against thermo-oxidative degradation of the polymer, preferably in the form of solution in butadiene. To deactivate the catalyst it is preferable to use water or organic acids such as resin acids, or higher aliphatic alcohols (containing for example 8 to 18 carbon atoms in the molecule), or their combinations after subsequent treatments, in quantities such as to exceed overall the sum of the catalytic components by at least 5-10 times in mols. To the "short-stopper" other than acids are preferably added basifying agents soluble in it, such as ammonia, amines, epoxides and organic salts (alcoholates and carboxylates) of alkaline metals. In addition to the usual antioxidant compounds used to preserve the polymer, such as sterically inhibited phenols and phosphites, radical capturing agents such as secondary amines and epoxides are preferably added to the hydrocarbon solution. The two solutions can conveniently be emulsified between them. The mass thus treated can be sent to an adjacent heated screw apparatus (solvent removing extruder), in which the volatile substances are removed by evaporation, operating at temperatures in the range of 100 to 180°C and atmospheric or near atmospheric pressure. This treatment serves to remove the unconverted butadiene, the eventual low boiling solvent introduced with the catalytic mixture, as well as the water introduced in excess of that required for the destruction of the catalytic system. The butadiene and eventual low boiling solvent are subjected to the usual treatments for their separation and recycling. Operating according to the process of this invention, a polybutadiene in dry and stabilized form is typically obtained, with a content of volatile substances below approximately 1% by weight. This polybutadiene furthermore has a 1,4-cis content generally above 97% and a Mooney viscosity (ML 1+4, 100°C) of 30 to above 80. By the process of this invention, it is therefore possible to obtain a linear polybutadiene free of gel and with a very high content of 1,4-cis units. This polymer requires no washing treatment for the separation of the catalytic residues. Moreover, the process of this invention is simple and convenient, requires low power consumption and presents no problems of ecological nature in view of the elimination of the discharges. The process described can also be utilized advantageously for the copolymerization of butadiene with other related diolefins such as, for example, isoprene, piperilene, obtaining copolymers with an essentially 1,4-cis structure. The following experimental examples are given by way of illustrations and do not constitute limits to this invention. EXAMPLE 1 Preparation of the catalytic solution A 12×55 mm teflon coated metal plate is introduced in a heavy-walled glass bottle with a capacity of approximately 100 ml, after which the following are introduced in order: The bottle is stoppered with a neoprene sealed perforated crown stopper and transferred to a water bath thermostatically controlled at 80°C. By means of a revolving magnet, the metal plate is set in whirling agitation. After 5 minutes, 0.08 ml of HCl in 37% aqueous solution (C. Erba) is added to the reaction mixture by means of a micro syringe inserted through the rubber seal. After about 80 minutes the color of the suspension turns from grayish to nut-brown. The reaction is pursued for a total of three hours at 80°C. The resulting dense solution, titered after it has been allowed to rest for three hours at ambient temperature, exhibits an Nd content of 0.343 mol/l. Over approximately 5 minutes it is transferred slowly to a glass flask which already contains 820 ml of 0.97 molar solution of (i.C₄H₉)₂AlH in paraffin oil under mechanical agitation, introduced beforehand in the flask in dry N₂ atmosphere. The solution thus obtained is held for 24 hours at ambient temperature before use. Elementary analysis reveals the following molarities. Polymerization - Reference test The polymerization reactor consists of a steel cylinder arranged horizontally, with a capacity of approximately 2.8 1, equipped with a mechanical agitator capable of mixing high viscosity masses. In the upper part of the reactor there is a device conveying the vapors produced by the reaction to an external condenser and metering pump. The reactor is also equipped with a heating jacket with built-in electrical resistance. The charging of reagents is done by placing the reactor under vacuum (0.1 torr) and connecting it to a bottle containing butadiene, from which 1000 g are transferred. After thermostating at 60°C, 19.4 ml (equal to 0.52 mmols of Nd) of the above described catalytic solution are introduced in an autoclave. The pressure of 6.7 atm, reached by thermostating and obtained in the entire butadiene recycling installation, is maintained constant (together with the temperature of the reaction mass) throughout the test, since the vapors developed are continuously conveyed in a 4×6 mm coil immersed in a bath at -78°C, collected in a cylindrical tank with level indicator and returned to the reactor. The temperature of the liquid inside the tank is approximately minus 15°C thanks to an immersed coil in which a refrigerating mixture circulates. The dispersion of reactor heat to the atmosphere is partially compensated by the heating jacket, whose temperature is held at approximately 2°C above that of the reaction mass. The speed of the agitator is 40 rpm. The reaction is terminated 38 minutes after the addition of the catalyst by introduction of 0.5 1 of distilled and deaerated H₂O. The unreacted butadiene is removed by depressurizing and applying a vacuum in the autoclave at 60°C. The polymer is removed from the various locations inside the reactor (shaft, walls, etc.: 7 in all) and the various aliquots are dried and characterized separately. The Mooney viscosity values 1+4, 100° : ML) are as follows: The conversion with respect to the initial butadiene amounts to 48%. EXAMPLE 2 A polymerization of the butadiene is carried out in the same equipment and with the same reagents as used for the test of Example 1, with the difference that the initial thermostating temperature is 20°C instead of 60°C. The reaction, initiated with the addition of the catalyst, is pursued for 10 minutes at 20°C by the methods already described (recycling of condensed vapors, etc.: see Example 1). Then the vapor conveying valve at the head of the reactor is closed and the temperature of the jacket is set at 62°C. Within 10 more minutes, approximately, the internal temperature reached 60°C and at this point the external circuit of the vapors produced by the reaction is restored. The polymerization is interrupted with H₂O (see Example 1) 33 minutes after the beginning by the evidently greater effort of the agitator, whose absorbed power is more than tripled, as indicated by the reading of an ammeter. The polymer produced, sampled as already described, exhibits the following Mooney viscosities: Global conversion amounts to 56.7% EXAMPLE 3 Operating according to the methods of Example 2, with the equipment and reagents therein described, the butadiene is polymerized as before with the difference that in the second step the temperature is set at 50°C instead of 60°C. Also, the first step at 20°C is continued for 17 minutes. The duration of the test is 58 minutes from the introduction of the catalyst. The polymer produced yields the following values: The butadiene conversion is 40.2%. EXAMPLE 4 A polymerization test such as described in Examples 2 and 3 is carried out, the only difference being that the temperature of the second phase is 70°C. The reaction is interrupted after 40-1/2 minutes from the beginning and the dry polymer is characterized in the usual manner. The results indicate the following values: Conversion 61%.

Claims: A solvent-less 2-stage process for preparing a constant-viscosity cis-1 ,4-polybutadiene by catalytic polymerization of butadiene, comprising the steps of: preparing a catalytic mixture by contacting, in an inert hydrocarbon medium: a) at least one neodymium compound selected from among neodymium oxide, alkoxides, phenates and carboxylates; b) at least one organic compound containing hydroxyl (alcoholic or phenolic) or carboxylic groups, selected from among alcohols, phenols, and carboxylic acids, water being optionally added; c)at least one halogenated compound selected from among secondary or tertiary alkyl halides, aryl or alkylaryl halides, organic acid halides, metal or organometallic halides, hydrogen halide acids and halogens, and d) at least one aluminium organometal compound or a hydride derivative thereof, the quantities of the compounds a) and b) being such that the ratio of the hydroxyl groups (those of water included) and/or carboxyl groups to the neodymium atoms is from 2:1 to 80:1, said components being contacted so as to obtain a catalytic mixture wherein the Al/Nd atomic ratio is from 20:1 to 80:1 and the halogen/Nd atomic ratio is from 0,2:1 to 3:1; continuously or discontinuously feeding said catalytic mixture and liquid butadiene monomer, optionally pre-mixed, in the proportion of between 4. 10⁴ and 4. 10⁵ gram.mol of butadiene per gram.atom of Nd and carrying out the polymerization until obtaining a mixture having a polymer content of from about 25% to about 70% by weight, characterized in that the polymerization is carried out in a first stage at a temperature lower than 30°C and is discontinued as soon as a 5% to 20% conversion of butadiene into cis-1,4-polybutadiene is attained, and in a second stage is at a temperature of from 50°C to less than 90°C, and discharging said polymeric mixture, wherefrom the constant-viscosity cis-1 ,4-polybutadiene is separated and recovered. Process according to claim 1, characterized in that the hydrocarbon medium for the catalyst is selected from butane, pentane, hexane and heptane or their mixtures, paraffin oil or hydrocarbon oils for oil-extended polybutadiene formulations. Process according to claim 1, characterized in that the neodymium compounds are selected from neodymium oxide (Nd₂O₃), neodymium tributylate, neodymium trinaphthenate and neodymium tri(2-ethylhexanoate). Process according to claim 1, characterized in that the hydroxyl-containing and the carboxyl-containing organic compounds are selected from butyl alcohol, 2-ethylhexanoic acid and the naphthenic acids. Process according to claim 1, characterized in that the halogenated compounds are selected from hydrochloric acid, diethylaluminium chloride, tert.butyl chloride, benzyl chloride and benzoyl chloride. Process according to claim 1, characterized in that the organometal aluminium compounds and their hydride derivatives are selected from aluminium trialkyl and aluminium alkyl hydrides. Process according to claim 6, characterized in that the aluminium organometal compounds are selected from aluminium triethyl, aluminium triisobutyl and aluminium diisobutyl monohydride. Process according to claim 1, characterized by adding water to the catalyst in such a quantity that the ratio of the aluminium atoms of the aluminium organometal compound, or of its hydride derivative, to the added mols of water is from 1:1 to 5:1. A process according to claim 8, characterized in that said ratio is of the order of 2:1. Process according to claim 1, characterized in that the ratio of hydroxyl groups (including those of the water) and/or carboxyl groups to neodymium atoms is of the order of 3:1 to 30:1, the ratio of the aluminium atoms to the neodymium atoms is of the order of 25:1 to 50:1, and the ratio of the halogen atoms to the neodymium atoms is of the order of 1:1-2:1. Process according to claim 1, characterized in that the working pressure in the first polymerization stage is below 3,5 bar absolute and in the second Polymerization stage is from 0.35 MPa (3,5 bar) absolute to 1.8 MPa (18 bar) absolute. Process according to claim 1, characterized in that the residence time of the monomer and the catalytic mixture is from 10 min to 120 min for both the polymerization stages. Process according to claim 12, characterized in that said residence time is in the order of 20 to 60 min. Process according to claim 1, characterized in that the first polymerization stage is carried out in a stirred homogeneous reactor, and the second polymerization stage is carried out in an apparatus of the self-cleaning single- or double-extruder type. Process according to claim 1, characterized in that the polymerization is carried out discontinuously in a stirred reactor under two different pressures for the two polymerization stages. Process according to claim 1, characterized in that the butadiene monomer which evaporates during polymerization is condensed and recycled directly to either polymerization stage. Process according to claim 1, characterized in that polymerization arresting agents and stabilizers against thermo-oxidative degradation are added to the mixture for which polymerization has been completed in a mixing device serially connected to the last polymerization reactor. Process according to claim 17, characterized in that the polymerization arresting agents are selected from water, organic acids and C₈-C₁₈ aliphatic alcohols. Process according to claim 18, characterized in that basifying compounds selected from ammonia, amines, epoxides and organic salts, which are alkoxides and carboxylates of alkali metals, are added to the water or the alcohols. Process according to claim 19, characterized in that antioxidants and radical-capturing agents such as secondary amines and epoxides are associated with the polymerization arresting agents. Process according to any of claims 17 to 20, characterized in that said polymerization arresting agents and said radical-capturing agents are fed in the form of an emulsion in the presence of liquid butadiene. Process according to claim 1, characterized in that the polymerization mixture with its additives is freed of low-boiling substances by operating at a temperature of between 100°C and 180°C under atmospheric pressure in a heated screw device which is serially connected with the mixing device claimed in claim 17.

Inventors: CARBONARO, ANTONIO, CUCINELLA, SALVATORE, GORDINI, SILVANO
Applicants: ENICHEM ELASTOMERI S.P.A.
Application year: 1986
Main classification: C08F36
IPC codes: C08F36, C08F2, C08F6, C08F4