Components and catalysts for the polymerization of olefins

Abstract: Catalyst components for the polymerization of olefins and catalysts obtained therefrom, said components comprising a porous metal oxide on which a magnesium dihalide, and a titanium halide or titanium halogen alcoholate and a compound containing two or more ether groups having specific reactivity properties towards MgCl₂ and TiCl₄ are supported.

Description: The present invention relates to catalyst components for the polymerization of olefins and catalysts obtained therefrom . In a previous patent application of the Applicant (published European application EP-A-0361494) catalyst components for the polymerization of olefins have been described, said components being obtained by supporting on an anhydrous magnesium halide, in active form, a titanium halide and an electron donor compound selected from compounds containing two or more ether groups, having specific reactivity properties towards magnesium chloride and titanium tetrachloride. Typical ethers are represented by the formula: where R, R₁ and R₂ are the same or different from each other and are hydrocarbyl radicals, and R₁ and R₂ can also be hydrogen. The catalyst component described in said EP-A-0361494 (date of publication: April 14, 1990) does not belong to the class of supported catalyst components. The presence of polyethers in catalysts is known by GB-A-966025. Said polyethers are used as additives in polyethylene catalysts only and their effect is to increase the linearity of polyethylene. They have a structure different from the ones in the catalyst component of the present invention. Catalyst components supported on silica are already known. For instance, WO-A-89/02446 describes silica supported magnesium-containing catalysts not containing inside electron-donor compounds. Said catalysts, suitable for polymerizing propylene, are more active in absence of inside electron-donor compounds. Now it has been found that is possible to prepare highly active and stereospecific catalysts for the polymerization of olefins starting from solid catalyst components obtained by reacting a titanium halide or titanium halogen alcoholate and an electron donor compound, selected from compounds with two or more ether groups as described in EP-A-0361494, with the solid obtained by impregnating a porous metal oxide, such as silica or alumina, or mixtures thereof with a solution of magnesium dihalide or of a magnesium compound which can be transformed into a dihalide through a reaction with halogenating agents. Surprisingly, the catalysts of the invention are much more active and stereospecific than the catalysts supported on metal oxides and obtained from electron-donor compounds other than the ether compounds used in the catalysts of the invention. More specifically, the catalyst components of the invention comprise a porous metal oxide on which a magnesium dihalide and a titanium halide or titanium halogen alcoholate and an electron-donor compound containing two or more ether groups are supported, said electron-donor compound being capable of complexing with anhydrous magnesium dichloride in a quantity not greater than 60 mmoles per 100 g of MgCl₂ and being unreactive with TiCl₄ to give substitution reactions, or being capable of reacting in this manner for less than 50% in moles. By titanium and magnesium compounds and electron-donor compounds supported on porous metal oxide it is meant those compounds which are physically fixed on the oxide and/or chemically combined with the oxide; possibly the titanium and magnesium compounds and the electron-donors, which are supported on the porous metal oxide, may also be chemically combined with each other. In the supported components the Mg/Ti molar ratio is from 0.5:1 to 10:1, in particular from 4:1 to 6:1, and the molar ratio Ti/electron-donor compound is from 0.5:1 to 3:1. The metal oxide is present in quantities greater than 40% by weight with respect to the total weight of the component. The metal oxides have a porosity greater than 0.3 cm³/g, preferably from 1 to 3 cm³/g. The surface area is greater than 30 m²/g (BET) and in particular greater than 100 m²/g. The preferred oxides such as silica and alumina, have in general a surface area from 100 to 400 m²/g. The metal oxides generally contain hydroxyl surface groups (e.g. in an amount of from 1 to 5 mmoles/g of oxide), but may also have none of them. Preferably the oxides are used in the anhydrous state, i.e., free from chemically uncombined water. Chemically uncombined water, however, can be present in a quantity smaller than 30 mmoles/g of oxide. Said water can be removed by submitting the oxides to heating at temperatures from 150° to 250°C. The amount of hydroxyl groups is controlled by calcining the oxides at temperatures usually from 250°C to 900°C (the higher the temperature the smaller the number of hydroxyls present). Different methods are used for the preparation of the catalyst component. The preferred method consists in impregnating the metal oxide by suspending it 1) in a solution of magnesium chloride in an organic solvent, such as an alcohol or an ether, or 2) in a hydrocarbon solution (hexane, heptane) of a MgCl₂.nTi(OR)₄ complex where n is a number from 1 to 3, and R is an C₂₋₈ alkyl, C₃₋₈ cycloalkyl or C₆₋₈ aryl radical and then evaporating the solvent. The oxide thus obtained is then reacted with an excess of TiCl₄ containing an ether compound in solution at temperatures from 60° to 135°C. The solid is separated hot from the excess of TiCl₄ and then washed thoroughly with hexane or heptane until there are no chlorine ions in the wash . The treatment with TiCl₄ may be repeated. It is also possible to react a magnesium impregnated metal oxide, first with the ether compound and then with the titanium tetrachloride. The ether compound can also be added during the impregation of the metal oxide, or can be reacted after the reaction with the titanium compound. In this case, it is best to conduct the reaction in the presence of an aromatic solvent, such as benzene and toluene. When the metal oxides are used with magnesium compound solutions other than magnesium halides, it is best to convert said compounds into halides by reacting them with halogenating agents, such as SiCl₄, Al-alkyl halides, and Cl₃SiR. The oxide thus impregnated and treated is then reacted with TiCl₄ and with the ether compound following the methods indicated above. Suitable magnesium compounds which are other than the magnesium halides include RMgX, MgR₂, Mg(OR)₂, XMgOR, MgX₂nTi(OR)₄ where X is Cl or Br, R is a C 1-18 alkyl or C₃₋₁₈ cycloalkyl radical, and n is from 1 to 4. Preferred ether compounds have the following general formula: where R, R₁ and R₂ are the same or different from each other and are C₁₋₁₈ alkyl, C₃₋₁₈ cycloalkyl, C₆₋₁₈ aryl, and C₇₋₁₈ aralkyl or alkaryl radicals and R₁ and R₂ can also be hydrogen atoms. In particular, R is a C₁₋₆ carbon alkyl radical, and preferably a methyl. Moreover, when R₁ is methyl, ethyl, propyl or isopropyl, R₂ can be ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, 2-ethylhexyl, cyclohexyl, methylcyclohexyl, phenyl or benzyl; when R₁ is hydrogen, R₂ can be ethyl, butyl, sec.butyl, tert-butyl, 2-ethylhexyl, cyclohexylethyl, diphenylmethyl, p-chlorophenyl, 1-naphthyl or 1-decahydronaphthyl; R₁ and R₂ can also be the same and are ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, neopentyl, phenyl, benzyl or cyclohexyl. Representative examples of the ethers included in the formula indicated above are: 2-(2-ethylhexyl)-1,3-dimethoxypropane, 2-isopropyl-1,3-dimethoxypropane, 2-butyl-1,3-dimethoxypropane, 2-sec-butyl-1,3-dimethoxypropane, 2-cyclohexyl-1,3-dimethoxypropane, 2-phenyl-1,3-dimethoxypropane, 2-tert-butyl-1,3-dimethoxypropane, 2-cumyl-1,3-diethoxypropane, 2-(2-phenylethyl)-1,3-dimethoxypropane, 2-(2-cyclohexylethyl)-1,3-dimethoxypropane, 2-(p-chlorophenyl)-1,3-dimethoxypropane, 2-(diphenylmethyl)-1,3-dimethoxypropane, 2-(1-naphthyl)-1,3-dimethoxypropane, 2-(p-fluorophenyl)-1,3-dimethoxypropane, 2-(1-decahydronaphthyl)-1,3-dimethoxypropane, 2-(p-t-butylphenyl)-1,3-dimethoxypropane, 2,2-dicyclohexyl-1,3-dimethoxypropane, 2,2-diethyl-1,3-dimethoxypropane, 2,2-dipropyl-1,3-dimethoxypropane, 2,2-dibutyl-1,3-dimethoxypropane, 2,2-diethyl-1,3-diethoxypropane, 2,2-dipropyl-1,3-diethoxypropane, 2,2-dibutyl-1,3-diethoxypropane, 2-methyl-2-ethyl-1,3-dimethoxypropane, 2-methyl-2-propyl-1,3-dimethoxypropane, 2-methyl-2-benzyl-1,3-dimethoxyporpane, 2-methyl-2-methylcyclohexyl-1,3-dimethoxypropane, 2,2-bis(p-chlorophenyl)-1,3-dimethoxypropane, 2,2-bis(2-phenylethyl)-1,3-dimethoxypropane, 2,2-bis(2-cyclohexylethyl)-1,3-dimethoxypropane, 2-methyl-2-isobutyl-1,3-dimethoxypropane, 2-methyl-2-(2-ethylhexyl)-1,3-dimethoxypropane, 2,2-bis(2-ethylhexyl)-1,3-dimethoxypropane, 2,2-bis(p-methylphenyl)-1,3-dimethoxypropane, 2-methyl-2(2-ethylhexyl)-1,3-dimethoxypropane, 2,2-bis(2-ethylhexyl)-1,3-diethoxypropane, 2,2-bis(p-methylphenyl)-1,3-dimethoxypropane, 2-methyl-2-isopropyl-1,3-diethoxypropane, 2,2-diisobutyl-1,3-dimethoxypropane, 2,2-diphenyl-1,3-dimethoxypropane, 2,2-dibenzyl-1,3-dimethoxypropane, 2,2-bis(cyclohexylmethyl)-1,3-dimethoxypropane, 2,2-diisobutyl-1,3-diethoxypropane, 2,2-diisobutyl-1,3-dibutoxypropane, 2-isobutyl-2-isopropyl-1,3-dimethoxypropane, 2,2-di-sec-butyl-1,3-dimethoxypropane, 2,2-di-tert-butyl-1,3-dimethoxypropane, 2,2-dineopentyl-1,3-dimethoxypropane, 2-isopropyl-2-isopentyl-1,3-dimethoxypropane, 2-phenyl-2-benzyl-1,3-dimethoxypropane, 2-cyclohexl-2-cyclohexylmethyl-1,3-dimethoxypropane, 2,2-diisopentyl-1,3-dimethoxy propane. Preferably, these ethers form complexes with magnesium dichloride in quantities equal to 20-50 mmoles per 100 g of MgCl₂ and react with TiCl₄ for less than 30% in moles. Other ethers that can be used are: 2,3-diphenyl-1,4-diethoxybutane, 2,3-dicyclohexyl-1,4-diethoxybutane, 2,3-dibenzyl-1,4-diethoxybutane, 2,3-dibenzyl-1,4-dimethoxybutane, 2,3-dicyclohexyl-1,4-dimethoxybutane, 2,3-diisopropyl-1,4-dimethoxybutane, 2,3-diisopropyl-1,4-diethoxybutane, 2,2-bis(p-methylphenyl)-1,4-dimethoxybutane, 2,3-bis(p-chlorophenyl)-1,4-dimethoxybutane, 2,3-bis(p-fluorophenyl)-1,4-dimethoxybutane, 2,4-diphenyl-1,5-dimethoxypentane, 2,5-diphenyl-1,6-dimethoxyhexane, 2,4-diisopropyl-1,5-dimethoxypentane, 2,5-diphenyl-1,6-dimethoxyhexane, 3-methoxymethyltetrahydrofuran,3-methoxymethyldioxane, 1,1-dimethoxymethyl-1,2,3,4-tetrahydronaphtalene, 1,1-dimethoxymethyldecahydronaphthalene, 1,1-dimethoxymethylindan, 2,2-dimethoxymethylindan, 1,1-dimethoxymethyl-2-isopropyl-5-methylcyclohexane, 1,3-diisobutoxypropane, 1,2-diisobutoxyethane, 1,3-diisoamyloxypropane, 1,2-diisoamyloxyethane, 1,3-dineopentoxypropane, 1,2-dineopentoxyethane, 2,2-tetramethylene-1,3-dimethoxypropane, 2,2-pentamethylene-1,3-dimethoxypropane, 2,2-hexamethylene-1,3-dimethoxypropane, 1,2-bis(methoxymethyl)cyclohexane, 2,8-dioxaspiro[5,5]undecane, 3,7-dioxabicyclo[3,3,1]nonane, 3,7-dioxabicyclo[3,3,0]octane, 3,3-diisobutyl-1,5-dioxane, 6,6-diisobutyldioxepane, 1,1-dimethoxymethylcyclopropane, 1,1-bis(methoxymethyl)cyclohexane, 1,1-bis(methoxymethyl)bicyclo[2,2,1]heptane, 1,1-dimethoxymethylcyclopentane, 2-methyl-2-methoxymethyl-1,3-dimethoxypropane. Particularly preferred ethers are the 1,3-diethers where R is methyl and R₁ and R₂, are the same or different from each other and are selected among methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, iso-pentyl, 2-ethylhexyl, cyclohexyl, methylcyclohexyl, phenyl, and benzyl, and when R₁ is hydrogen, R₂ is ethyl, butyl, sec.butyl, tert-butyl, 2-ethylhexyl, cyclohexyl, diphenylmethyl, p-chlorophenyl, 1-naphthyl, 1-decahydronaphthyl. Particularly preferred ethers are 2,2-diisobutyl-1,3-dimethoxypropane, 2-isopropyl-2-isopentyl-1,3-dimethoxypropane, 2,2-di-n-propyl-1,3-dimethoxypropane, 2,2-diisopentyl-1,3-dimethoxypropane, 2,2-dicyclohexyl-1,3-dimethoxypropane. The complexing test of the ethers with MgCl₂ is carried out as follows: In a 100 ml glass flask equipped with a mechanical agitator having fixed blades are introduced in nitrogen atmosphere in order: 70 ml of anhydrous n-heptane 12 mmoles of anhydrous MgCl2 activated as described below 2 mmoles of ether. The mixture is reacted at 60°C for 4 hours (agitator speed 400 rpm). It is then filtered and washed at room temperature with 100 ml of n-heptane and dried with a mechanical pump. The solid is characterized, after having been treated with 100 ml of ethanol, by gas chromatographic quantitative analysis for the analysis of the quantity of ether fixed. The test of the reaction with TiCl₄ is carried out as follows: In a 25 ml test-tube with a magnetic agitator - in nitrogen atmosphere - are introduced in order: 10 ml of anhydrous n-heptane 5 mmoles of TiCl₄ 1 mmole of donor The mixture is reacted at 70°C for 30 minutes, then cooled to 25°C and decomposed with 90 ml of ethanol. The solutions obtained are analyzed by gas chromatography, by using the standard internal method, with an HRGC Mega Series Carlo Erba gas chromatograph with a 25 meters Chrompack CP-SIL capillary column. The magnesium chloride used in the complexing test with the ethers is prepared as follows. In a 1 liter vibrating mill jar (Vibratrom from Siebtechnik) containing 1.8 Kg of steel spheres of 16 mm diameter, 50 g of anhydrous MgCl₂ and 6.8 ml of 1,2-dichloroethane (DCE) are introduced in nitrogen atmosphere. It is ground at room temperature for 96 hours, there after the solid recovered is kept under vacuum in the mechanical pump for 16 hours at 50°C. Characterization of the solid: Half peak breadth of the reflection D110 = 1.15 cm Presence of a halo with maximum intensity at 2ϑ = 32.1° Surface area (B.E.T.) = 125 m²/g DCE residue = 2.5% by weight. The catalyst components of the present invention form, with Al-alkyl compounds, catalysts for the polymerization of CH₂ = CHR olefins, where R is hydrogen, or a 1-6 carbon alkyl radical, or an aryl. In case of the stereoregular polymerization of olefins, particularly propylene, it may be advantageous in some cases to use, together with the Al-alkyls, also an electron-donor compound selected among 2,2,6,6-tetramethylpiperidine and silicon compounds containing at least one Si-OR link where R is a hydrocarbyl radical. Preferably the silicon compounds have the formula R I R II Si(OR III )OR IV where R I and R II , are the same different from each other are branched C₃ to C₁₂ alkyl radicals, or C₃ C₁₂ cycloaliphatic radicals, or 6-12 carbon aryls; R III and R IV , independently, are 1-6 carbon alkyl radicals. Examples of said representative compounds are: tert(butyl)₂Si(OCH₃)₂; (cyclohexyl)₂ Si(OCH₃)₂; (cyclopentyl)₂ Si(OCH₃)₂; (isopropyl)₂ Si(OCH₃)₂; (sec.butyl)₂ Si O(CH₃)2. Other examples of silicon compounds are phenyltriethoxysilane, ethyltriethoxysilane, propyltriethoxysilane, chloroethyltriethoxysilane, chlorophenyltriethoxysilane, neopentyltriethoxysilane, octyl trimethoxysilane, isopropyl-triethoxysilane, n-butyltriethoxysilane, n-octyl-trimethoxysilane. The Al-alkyl compounds comprise the Al-trialkyl compounds, such as Al-triethyl, Al-triisobutyl, Al-trin.butyl. Linear or cyclic Al-alkyls containing 2 or more Al atoms linked to each other by O, N, S atoms may also be used. Examples of these compounds are: (C₂H₅)₂ Al-O-Al(C₂H₅)₂ ; where n is a number from 1 to 20. The Al-alkyl compound is used in Al/Ti molar ratios usually of from 1 to 1000. Al-Alkyl compounds can be used in mixture with Al-alkyl halides such as AlEt₂Cl. The molar ratio between the Al-alkyl compound and the electron-donor compound added to the Al-alkyl compound is usually from 5:1 to 100:1. As indicated, the catalysts are suitable for the (co)polymerization of CH₂=CHR olefins where R has the above indicated meaning, and in particular for the homo- and copolymerization of propylene to form isotactic polypropylene, crystalline copolymers of the propylene with minor proportions of ethylene, and optionally butene, and similar higher alpha-olefins, or impact grade polypropylene obtained by polymerization of the propylene, alone or with ethylene and/or another alpha-olefin followed by at least another polymerization step in which an olefin elastomeric polymer is formed. The catalysts can be used in the preparation of HDPE, LLDPE, and elastomeric ethylenepropylene copolymers containing optionally minor proportions of a diene (e.g. EP and EPDM rubbers). The polymerization of olefins is carried out according to known methods operating in liquid phase formed by the monomer, or monomers, or by their solutions in hydrocarbon solvents, such as hexane and heptane, or in gas phase, or with mixed liquid-gas techniques. The polymerization temperature is generally from 0° to 150°, preferably from 60° to 100°C, and is carried out at atmospheric pressure or higher. The catalysts can be precontacted with small quantities of olefin (prepolymerization) in order to improve the catalytic activity and/or morphology of the polymer. The prepolymerization is carried out maintaining the catalyst in suspension in a hydrocarbon medium (hexane, heptane, etc.) and allowing small quantities of monomer to go through, maintaining the temperature from room temperature to 60°C, until a quantity of polymer is produced which is between 0.5 and 3 times the weight of the solid catalyst component. The prepolymerization can also take place in liquid monomer, or in gas phase, under the temperature conditions mentioned above, thus producing quantities of polymer up to 1000 times the weight of the solid catalyst component. The following examples are given to illustrate the invention. Examples 1 to 9 (Preparation of the said catalyst component.) 15 g of silica (Grace 952) calcined at 150°C for 8 hrs are treated with 90 ml of (CH₃)₃SiCl in reflux for 16 hrs. It is filtered and washed with anhydrous n-heptane at 60°C until all traces of (CH₃)₃SiCl are eliminated, then dried by a mechanical pump. 30 g of alumina (Ketjen grade B) are calcined under vacuum at 150°C for 6 hrs. The silica and alumina thus treated are supported with the Mg compound according to the Methods set forth below. Method A 3.8 g of pre-treated silica are suspended in inert atmosphere in 20 ml of anhydrous n-heptane. Then 17.5 mmoles of MgCl₂.2,2Ti(OBu)₄ prepared by dissolving a suitable quantity of MgCl₂ in Ti(OBu)₄ at 140°C per 4 hrs, are added. The mixture is reacted for 4 hrs at 90°C in a rotavapor flask and then the solvent is evaporated under vacuum. Method B 4 g of pre-treated silica are suspended in 30 ml of anhydrous ethanol containing 18 mmoles of MgCl₂. The mixture is reacted for 4 hrs at 70°C in a rotavapor flask and then the ethanol is evaporated until a residual content of 3 moles of ethanol per mole of MgCl₂ is reached. Method C 4 g of pre-treated silica are suspended in 30 ml of anhydrous hexane containing 18 mmoles of Mg(n-hexyl)2. The mixture is reacted for 4 hrs at 70°C in a rotavapor flask, then the hexane is evaporated. The solid thus obtained is treated with 50 ml of SiCl₄ in reflux for 4 hrs, then filtered, washed with hexane and vacuum dried. Method D 4 g of pre-treated alumina are suspended, in inert atmosphere, in 20 ml of anhydrous n-heptane and then 18 mmoles of MgCl₂ 2.2Ti(OBu)₄ are added. The mixture is reacted for 4 hrs at 70°C in a rotavapor flask and then the solvent is evaporated under vacuum. Reaction with TiCl₄ The silica (methods A, B, C,) and the alumina (method D) supported with the Mg compound are added in inert atmosphere, slowly, under agitation and at room temperature, to 200 ml of TiCl₄, then 5.85 mmoles of a compound containing ether groups are added. The mixture is heated to 100°C, reacted at this temperature for 2 hrs and then filtered. Another 200 ml of TiCl₄ are added, and the treatment is repeated at 100°C for 2 hrs: at the end it is filtered and washed with anhydrous n-heptane twice at 60°C, and 3 times at room temperature. The washing treatment has been carried out until no chlorine ions were not detectable in the wash. The ether compounds used and the composition of the catalyst components are shown in Table 1. Examples 10 to 18 (Propylene polymerization) Method 1 In a 2000 ml stainless steel autoclave with an anchor agitator, 1,000 ml of n-heptane, 2.5 mmoles of Al(C₂H₅)₃ and an adequate quantity of the solid catalyst component are introduced in propylene gas current at 20°C. The autoclave is closed after having brought the pressure to 1 atm by feeding propylene, and a hydrogen overpressure equal to 0.2 atm is introduced. The mixture is heated 70°C and the total pressure is brought to 7 atm with propylene. It is polymerized for 2 hours while the monomer is fed continuously, and the temperature is maintained at 70°C. The polymer obtained is then isolated by filtration and dried. The polymer remaining in the filtered product is precipitated with methanol, vacuum dried and considered in determining the total residue of the n-heptane extraction. The polymerization results and the properties of the polymers obtained are shown in Table 2. Method 2 In the autoclave described in method 1,20 ml of a heptane suspension containing an adequate quantity of the solid catalyst component, 5 mmoles of Al(C₂H₅)₃, 800 ml of hydrogen, and 500 g of propylene are introduced at 20°C under vacuum, and then heated to 70°C and polymerized for two hours. The polymer obtained is dried and characterized. The polymerization yields and properties of the polymers obtained are shown in Table 2. Example 19 (Ethylene polymerization) In a 2000 ml stainless steel autoclave with an anchor agitator , a suspension containing in 1000 ml of n-heptane, 2.5 mmoles of Al(C₂H₅)₃ and 25 mg of the solid catalyst component of example 2 are introduced under vacuum at 65°C. Then 4.5 atm of hydrogen and ethylene are introduced until a total pressure of 11.5 atm is reached. The mixture is polymerized at 75°C for 3 hours while continuing to feed the monomer. After filtration and drying, 125 g of polyethylene with an intrinsic viscosity of 1.8 dl/g and bulk density of 0.41 g/ml are isolated. Example 20 (Propylene/ethylene polymerization) In the autoclave described in example 17 are introduced under vacuum at 20°C: 500 g of propylene 5 mmoles of Al(iso-C₄H₉)₃ an ethylene overpressure equal to 3.5 atm A heptane suspension containing 30 mg of the catalytic component of ex. 2 is injected under argon pressure. It is then polymerized at 20°C while continuing to feed the ethylene for 1 hour. After having removed the unreacted monomers, 75 g of polymer are obtained (40% propylene, 4% crystallinity under X-rays).

Claims: A catalyst component for the polymerization of olefins comprising a porous metal oxide, on which a magnesium dihalide and a titanium halide or titanium halogen alcoholate, and an electron-donor compound containing two or more ether groups are supported, said electron-donor compound being capable of complexing with anhydrous magnesium dichloride in a quantity not greater than 60 mmoles per 100 g of MgCl₂ and being unreactive with TiCl₄ to give substitution reactions, or being capable of reacting in this manner for less than 50% in moles; the ether complexing test with MgCl₂ being conducted as follows: in a 100 ml glass flask with fixed blades mechanical agitator are introduced in a nitrogen atmosphere, in order: 70 ml anhydrous n-heptane 12 mmoles activated anhydrous MgCl₂ 2 mmoles ether; the ingredients are heated at 60°C for 4 hours (stirring speed 400 rpm), then filtered and washed at room temperature with 100 ml n-heptane and dried with mechanical pump; the quantity of ether complexed is determined, after treatment of the solid with 100 ml of ethanol by quantitative gas chromatic analysis; the activated magnesium chloride used in the complexing test with the ethers being prepared as follows: in a 1 liter vibrating mill jar (Vibratrom from Siebtechnik) containing 1.8 Kg of steel spheres of 16 mm diameter, 50 g of anhydrous MgCl₂ and 6.0 ml of 1,2-dichloroethane (DCE) are introduced in nitrogen atmosphere; it is ground at room temperature for 96 hours, whereupon the solid recovered is kept under vacuum in the mechanical pump for 16 hours at 50°C and has the following characterization; half peak breadth of the reflection D110 = 1.15 cm presence of a halo with, maximum intensity at 2ϑ = 32.1° surface area (B.E.T.) = 125 m²/g DCE residue = 2.5% by weight; and the test for reactivity of the ethers with TiCl₄ being conducted as follows: in a 25 ml test tube with a magnetic agitator are introduced, in a nitrogen atmosphere, in order: 10 ml anhydrous n-heptane 5 mmoles TiCl₄ 1 mmole ether donor; the ingredients are heated at 70°C for 30 min, then cooled at 25°C and decomposed with 90 ml of ethanol; the solution obtained is analyzed gas chromatographically using the method of internal standard with a Carlo Erba HRGC 5300 Mega Series gas chromatograph with a 25 meters Chrompack CP-SIL capillary column; in which catalyst component the Mg/Ti molar ratio is from 0.5:1 to 10:1, the Ti/electron donor compound molar ratio is from 0.5:1 to 3:1 and the metal oxide is present in a quantity greater than 40% by weight with respect to the total weight of the component. The catalyst component of claim 1, where the titanium halide is tetrachloride and the magnesium dihalide is dichloride. The catalyst component of claim 1, where the metal oxide is selected from the group consisting of silica, alumina, and mixtures thereof. The catalyst component of claim 1 where the compound containing ether groups is selected from compounds having the general formula where R, R₁ and R₂, are the same or different from each other and are C₁₋₁₈ alkyl, C₃₋₁₈ cycloalkyl, C₆₋₁₈ aryl, C₇₋₁₈ aralkyl or alkylaryl radicals, and R₁ and R₂ can also be hydrogen atoms. The catalyst component of claim 4 where R is methyl, and R₁ and R₂, are the same or different from each other and are selected among methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, iso-pentyl, 2-ethylhexyl, cyclohexyl, methylcyclohexyl, phenyl, and benzyl, and when R₁ is hydrogen, R₂ is ethyl, butyl, sec.butyl, tert-butyl, 2-ethylhexyl, cyclohexyl, diphenylmethyl, p-chlorophenyl, 1-naphthyl, 1-decahydronaphthyl. The catalyst component of claim 5 where the compound containing ether groups compound is selected among 2,2-diisobutyl-1,3-dimethoxypropane, 2-isopropyl-2-isopentyl-1,3-dimethoxypropane, 2,2-di-n-propyl-1,3-dimethoxypropane, 2,2-diisopentyl-1,3-dimethoxypropane, 2,2-dicyclohexyl-1,3-dimethoxypropane. A catalyst for the polymerization of olefins comprising the reaction product of the catalyst component of claim 1 and an Al-alkyl compound. A catalyst for the polymerization of olefins comprising the reaction product of the catalyst component of claim 3 and an Al-alkyl compound. A catalyst for the polymerization of olefins comprising the reaction product of the catalyst component of claim 5 and an Al-trialkyl compound. A catalyst for the polymerization of olefins comprising the reaction product of the catalyst component of claim 6 and an Al-trialkyl compound.

Inventors: ALBIZZATI ENRICO, GIANNINI UMBERTO DR CHEM, MORINI GIAMPIERO DR CHEM, ALBIZZATI, ENRICO, GIANNINI, UMBERTO, DR. CHEM., MORINI, GIAMPIERO, DR. CHEM.
Applicants: HIMONT INC, HIMONT INCORPORATED
Application year: 1990
Main classification: C08F4
IPC codes: C08F4, C08F10, C07F7