Catalyst, process for its preparation and process for polymerization of olefins using this catalyst

Abstract: Disclosed is a catalyst composition for use in the polymerization of olefins, which is comprised of (a) a catalyst component containing magnesium, titanium, a halogen, and an ingredient derived from an ester compound, and (b) an organic aluminum compound. The catalyst activity and capability of providing a highly stereoregular polymer are enhanced by preparing the catalyst component (a) by a process wherein, during or after the formation of a solid catalyst component containing magnesium, titanium, and a halogen, the solid catalyst component is treated with an ester of the formula: (R¹O) i (R²O) j (R³O) k -Z-COOR⁴ (I) wherein R¹, R², R³ and R⁴ are an aliphatic, alicyclic, aromatic, polycyclic or heterocyclic compound group, Z is an aliphatic or alicyclic hydrocarbon group in which hydrogen may be substituted with an aromatic or polycyclic group, and i, j and k are integers of 0 to 3 with the provisio that the sum of i, j and k is at least 1.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a catalyst composition showing a high activity for homopolymerizing or copolymerizing olefins. More particularly, it relates to a catalyst composition and a process for the preparation thereof which catalyst composition provides a highly stereoregular polymer in a high yield when the catalyst composition is used for the polymerization of an α-olefin having at least 2 carbon atoms, and a process for the polymerization of olefins. 2. Description of the Related Art Many proposals have been made on the process for the preparation of a catalyst component where a solid catalyst component comprising magnesium, titanium and halogen compounds and an electron donor, (i.e., an internal donor) as indispensable ingredients. In most of these proposals, an organic carboxylic acid ester is used as the electron donor, and there is a problem in that an ester smell is left in the formed polymer unless the ester is removed by washing with an organic solvent or the like means. Moreover, these catalyst components have a poor catalytic activity and provide a low stereospecificity. Methods using specific esters, that is, esters having an ether portion as the electron donor have been proposed as the means for overcoming these defects. For example, there can be mentioned a method using an anisic acid ester (Japanese Unexamined Patent Publication No. 48-18986), a method using a furan-carboxylic acid ester (Japanese Unexamined Patent Publication No. 59-129205 and No. 54-136590; U.S. Patent No. 4525555, No. 4,255,280 and No. 4,330,650), and a method using 2-ethoxyethyl acetate (Japanese Unexamined Patent Publication No. 61-287908) as well as a method for preparing stereospecific polyolefins in the presence of TiCl₃ or modified TiCl₃, organoaluminum, and - as the ester component - compounds of the general formula R¹OCR²:CR³CO₂R⁴ (R¹⁻⁴ = H, C₁₋₂₀ alkyl or alkenyl, or Ph or cyclohexyl with or without substituents) (Japanese Unexamined Patent Publication No. 55-36232). Even if these esters are used, however, industrially satisfactory performances cannot be obtained with respect to the catalytic activity and stereospecificity, and development of a catalyst having further enhanced performances is desired. SUMMARY OF THE INVENTION A primary object of the present invention is to provide a catalyst system having a high catalytic activity and being capable of providing a highly stereoregular olefin polymer, which is difficult to obtain by the conventional technique. In accordance with the present invention, there is provided a catalyst component for use in the polymerization of the olefins, which contains magnesium, titanium, a halogen, and an ingredient derived from at least one member selected from the group consisting of esters represented by the following formula (I) (R¹O) i (R²O) j (R³O) k -Z-COOR⁴ (I) wherein R¹, R², R³ and R⁴ independently represent an aliphatic hydrocarbon group, an alicyclic hydrocarbon group, an aromatic hydrocarbon group, a polycyclic hydrocarbon group, or a heterocyclic compound group, Z represents an aliphatic or alicyclic hydrocarbon group in which a hydrogen atom may be substituted with an aromatic group or a polycyclic group, and i, j and k are integers of from 0 to 3 with the proviso that the sum of i, j and k is at least 1, wherein said titanium, magnesium and ester of formula (I) are present at a molar ratio of 1 : 1 - 1,000 : 10⁻⁶ - 100. Furthermore, a catalyst composition for use in the polymerization of olefins, which comprises (a) the catalyst component according to the invention (b) an organic aluminum compound: said organic aluminum compound being selected from the group consisting of the compounds represented by the following general formulae (III) through (V): AlR⁹R¹⁰R¹¹ (III) R¹²R¹³Al-O-AlR¹⁴R¹⁵ (IV) and wherein R⁹, R¹⁰, and R¹¹ independently represent a hydrocarbon group having up to 12 carbon atoms, a halogen atom or a hydrogen atom, with the proviso that at least one of R⁹, R¹⁰ and R¹¹ represents a hydrocarbon group, R¹², R¹³, R¹⁴, and R¹⁵ independently represent a hydrocarbon group having up to 12 carbon atoms. R¹⁶ represents a hydrocarbon group having up to 12 carbon atoms, and ℓ is an integer of at least 1, wherein the amount of the organic aluminum compound is 0.5 to 1,000 moles per mole of titanium being present in said component (a), is provided. Still furthermore, the present invention provides a process for the preparation of the catalyst component according to the invention which comprises forming a solid catalyst component comprising magnesium, titanium and a halogen as indispensable ingredients and treating the solid catalyst component during or after its formation with at least one member selected from the group consisting of esters represented by the formula (I) or (II) as defined in claim 1 or 2, wherein the amounts of the magnesium compound, the titanium compound, and the ester of formula (I) are such that the resulting catalyst component contains titanium, magnesium, and the ester of formula (I) at a molar ratio of 1:1-1,000:10⁻⁶-100, respectively, more preferably at a molar ratio of 1:2-100:10⁻⁴-10, respectively, and a process for polymerizing an olefin which comprises contacting an olefin having 2 to 18 carbon atoms with the catalyst composition according to the invention, wherein the amount of the catalyst composition used is such that the amount of the organic aluminum compound is 10⁻⁴ to 20 millimoles per liter of the polymerization system. DESCRIPTION OF THE PREFERRED EMBODIMENTS As the magnesium compound used for the preparation of the solid catalyst component in the present invention, there can be mentioned magnesium halides such as magnesium chloride and magnesium bromide, magnesium alkoxides such an magnesium ethoxide and magnesium isopropoxide, magnesium salts of carboxylic acids such as magnesium laurate and magnesium stearate, and alkyl magnesium much as butylethyl magnesium. These magnesium compounds can be used alone or as a mixture of two or more thereof. A magnesium halide or a compound capable of forming a magnesium halide at the step of preparing the catalyst is preferably used. The compound having chlorine as the halogen is especially preferably used. As the titanium compound used for the preparation of the solid catalyst component in the present invention, there can be mentioned titanium halides such as titanium tetrachloride, titanium trichloride, and titanium tetrabromide, titanium alkoxides such as titanium butoxide and titanium ethoxide, and alkoxytitanium halides such as phenoxytitanium chloride. These compounds can be used alone or as a mixture of two or more thereof. A tetravalent titanium compound containing a halogen is preferably used, and titanium tetrachloride is most preferably used. As the halogen of the halogen-containing compound used for the preparation of the solid catalyst component in the present invention, there can be mentioned fluorine, chlorine, bromine and iodine, and chlorine is preferable. The kind of the halogen-containing compound practically used depends on the catalyst-preparing process, and as typical instances, there can be mentioned titanium halides such as titanium tetrachloride and titanium tetrabromide, silicon halides such as silicon tetrachloride and silicon tetrabromide, and phosphorus halides such as phosphorus trichloride and phosphorus pentachloride. In some preparation processes, halogenated hydrocarbons, halogen molecules and hydrohalogenic acids such as HCl, HBr and HI can be used. In another preferred embodiment of said process the solid catalyst component is prepared from a magnesium compound, preferably magnesium halide, a titanium compound, and a halogen-containing compound which may be the same as the magnesium compound or the titanium compound, preferably titanium tetrahalide. The ester compound used in the present invention is represented by the following general formula (I): (R¹O) i (R²O) j (R³O) k -Z-COOR⁴ (I) In the above general formula (I), R¹, R², R³, and R⁴, which may be the same or different, represent one or more of aliphatic hydrocarbon groups, alicyclic hydrocarbon groups, aromatic hydrocarbon groups, polycyclic hydrocarbon groups, and heterocyclic compound groups. When they are aliphatic or alicyclic hydrocarbon groups, those having 1 to 12 carbon atoms are preferable. For example, there can be mentioned methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, sec-butyl, tert-butyl, pentyl, hexyl, 3-methylpentyl, tert-pentyl, heptyl, i-hexyl, octyl, nonyl, decyl, 2,3,5-trimethylhexyl, undecyl, dodecyl, vinyl, allyl, 2-hexenyl, 2,4-hexadienyl, isopropenyl, cyclobutyl, cyclopentyl, cyclohexyl, tetramethylcyclohexyl, cyclohexenyl, and norbornyl groups. Hydrogen atoms of these groups may be substituted with halogen atoms. If any of R¹, R², R³, and R⁴ is an aromatic or polycyclic hydrocarbon group, an aromatic or polycyclic hydrocarbon group having 6 to 18 carbon atoms is preferable. As specific examples, there can be mentioned phenyl, tolyl, ethylphenyl, xylyl, cumyl, trimethylphenyl, tetramethylphenyl, naphthyl, methylnaphthyl, and anthranyl groups. Hydrogen atoms of these groups may be substituted with halogen atoms. If any of R¹, R², R³, and R⁴ is a heterocyclic compound groups, a heterocyclic compound group having 4 to 18 carbon atoms is preferable. As specific examples, there can be mentioned furyl, tetrahydrofuryl, thienyl, pyrrolyl, imidazolyl, indolyl, pyridyl, and piperidyl groups. Hydrogen atoms of these groups may be substituted with halogen atoms. If any of R¹, R², R³, and R⁴ is a group of an aromatic hydrocarbon, polycylic hydrocarbon, or heterocyclic compound, connected to an aliphatic hydrocarbon, a group of an aromatic hydrocarbon or polycyclic hydrocarbon haivng 6 to 18 carbon atoms or a group of a heterocyclic compound having 4 to 18 carbon atoms, connected to an aliphatic hydrocarbon having 1 to 12 carbon atoms, is preferable. As specific examples, there can be mentioned benzyl, diphenylmethyl, indenyl, and furfuryl groups. Hydrogen atoms of these groups may be substituted with halogen atoms. A divalent aliphatic or alicyclic hydrocarbon group having 1 to 20 carbon atoms, in which a hydrogen atom may be substituted with an aromatic or polycylic group having 6 to 18 carbon atoms, is preferable as Z in formula (I). As specific examples, there can be mentioned methylene, ethylene, ethylidene, trimethylene, tetramethylene, pentamethylene, hexamethylene, and propenylene groups. As examples of the substituted hydrocarbon groups, there can be mentioned methylmethylene, n-butylmethylene, ethylethylene, isopropylethylene, tert-butylethylene, sec-butylethylene, tert-amylethylene, adamantylethylene, bicyclo[2,2,1]heptylethylene, phenylethylene, tolylethylene, xylylethylene, diphenyltrimethylene, 1,2-cyclopentylene, 1,3-cyclopentylene, 3-cyclohexen-1,2-ylene, dimethylethylene, and inden-1,2-ylene groups. Hydrogen atoms of these groups may be substituted with halogen atoms. As specific examples of the ester compound of formula (I), there can be mentioned methyl methoxyacetate, ethyl methoxyacetate, butyl methoxyacetate, phenyl methoxyacetate, methyl ethoxyacetate, ethyl ethoxyacetate, butyl ethoxyacetate, phenyl ethoxyacetate, ethyl n-propoxyacetate, ethyl i-propoxyacetate, methyl n-butoxy acetate, ethyl i-butoxyacetate, ethyl n-hexyloxyacetate, octyl sec-hexyloxyacetate, methyl 2-methylcyclohexyoxyacetate, methyl 3-methoxypropionate, ethyl 3-methoxypropionate, butyl 3-methoxypropionate, n-octyl 3-ethoxypropionate, dodecyl 3-ethoxypropionate, pentamethylphenyl 3-ethoxypropionate, ethyl 3-(i-propoxy)propionate, butyl 5-(i-propoxy)propionate, allyl 3-(n-propoxy)propionate, cyclohexyl 3-(n-butoxy)propionate, ethyl 3-neopentyloxypropionate, butyl 3-(n-octyloxy)propionate, methyl 3-(2,6-dimethylhexyloxy)propionate, octyl 3-(3,3-dimethyldecyloxy)propionate, ethyl 4-ethoxybutyrate, cyclohexyl 4-ethoxybutyrate, octyl 5-(n-propoxy)valerate, ethyl 12-ethoxylaurate, ethyl 3-(1-indenoxy)propionate, methyl 3-methoxyacrylate, methyl 2-methoxyacrylate, methyl 2-ethoxyacrylate, ethyl 3-phenoxyacrylate, ethyl 2-methoxypropionate, n-butyl 2-(i-propoxy)butyrate, methyl 2-ethoxyisobutyrate, phenyl 2-cyclohexyloxyisovalerate, butyl 2-ethoxy-2-phenylacetate, allyl 3-neopentyloxybutyrate, methyl 3-ethoxy-3-(o-methylphenyl)propionate, ethyl 2-(o-methylphenyl)propionate, ethyl 3-ethoxy-2-mesitylpropionate, ethyl 3-ethoxy-2-tert-butylpropionate, ethyl 3-ethoxy-2-tert-amylpropionate, ethyl 3-ethoxy-2-adamantylpropionate, ethyl 3-ethoxy-2-bicyclo[2,2,1]heptylpropionate, ethyl 3-ethoxy-3-phenylpropionate, ethyl 3-ethoxy-3-mesitylpropionate, ethyl 3-ethoxy-3-tert-butylpropionate, ethyl 3-ethoxy-3-tertamylpropionate, propyl 4-ethoxy-2-(t-butyl)butyrate, ethyl 5-methoxy-2-methyl-1-naphthylnonanoate, ethyl 2-methoxycyclopentanecarboxylate, butyl 2-ethoxycyclohexanecarboxylate, isopropyl 3-(ethoxymethyl)tetralin-2-acetate, ethyl 8-butoxydecalin-1-carboxylate, methyl 3-ethoxynorbornane-2-carboxylate, methyl 2-(phenoxy)acetate, ethyl 3-(p-cresoxy)propionate, methyl 4-(2-naphthoxy)butyrate, butyl 5-carbazoloxyvalerate, methyl 2-phenoxypropionate, ethyl 3-(4-methylphenoxy)-2-phenylpropionate, ethyl 2-phenoxycyclohexanecarboxylate, ethyl thiophen-3-oxyacetate, ethyl 2-(2-picolinoxymethyl)-cyclohexanecarboxylate, and ethyl 3-furfuryloxypropionate. Among them, an alkoxy ester compound represented by the following general formula (II) is preferable. In the above formula (II), R⁵ and R⁶ independently represent an aliphatic hydrocarbon group having 1 to 20 carbon atoms, R⁷ and R⁸ independently represent a hydrogen atom or an aliphatic hydrocarbon group having 1 to 20 carbon atoms. Y represents a divalent linear hydrocarbon group having 1 to 4 carbon atoms, which is substituted with an aliphatic hydrocarbon group having 1 to 18 carbon atoms, an aromatic hydrocarbon group having 6 to 18 carbon atoms or a polycylic hydrocarbon group having 6 to 18 carbon atoms, or a divalent alicyclic hydrocarbon group having 3 to 12 carbon atoms. An alkoxy ester in which Y represents a linear hydrocarbon group having a bulky substituent having at least 4 carbon atoms at the second or third position counted from the carboxyl group is especially preferable. Furthermore, an alkoxy ester compound having a 4- to 8-membered cycloalkane is preferable. As specific examples, there can be mentioned ethyl 3-ethoxy-2-phenylpropionate, ethyl 3-ethoxy-2-tolylpropionate, ethyl 3-ethoxy-2-mesitylpropionate, ethyl 3-butoxy-2-(methoxyphenyl)propionate, methyl 3-i-propoxy-3-phenylpropionate, ethyl 3-ethoxy-3-phenylpropionate, ethyl 3-ethoxy-3-tert-butylpropionate, ethyl 3-ethoxy-3-adamantylpropionate, ethyl 3-ethoxy-2-tert-butylpropionate, ethyl 3-ethoxy-2-tert-amylpropionate, ethyl 3-ethoxy-2-adamantylpropionate, ethyl 3-ethoxy-2-bicyclo[2,2,1]heptylpropionate, ethyl 2-ethoxycyclohexanecarboxylate, methyl 2-(ethoxymethyl)cyclohexanecarboxylate and methyl 3-ethoxynorbornane-2-carboxylate. The process for the preparation of the catalyst used in the present invention is not particularly critical. A method can be adopted in which a magnesium compound such an a magnesium halide, a titanium compound such as a titanium halide and the ester of formula (I) are co-pulverized and the halogenation treatment is then carried out to increase the activity. Alternatively, a method can be adopted in which the magnesium compound is pulverized alone or in combination with a silicon compound or phosphorus compound and the titanium compound treatment and the halogenation treatment are carried out in the presence of the ester of formula (I). Moreover, a method can be adopted in which a magnesium carboxylate or magnesium alkoxide, the titanium compound, the halogenating agent and the ester of formula (I) are heat-treated to enhance the performances, or a method in which a magnesium halide is dissolved in an organic solvent and the ester of formula (I) is reacted in the presence of the titanium compound at or after the precipitation. Still further, a catalyst formed by adding the ester of formula (I) and titanium compound when the alkyl magnesium is reacted with the halogenating agent can be used. Still in addition, a catalyst formed by adding the ester of formula (I) and titanium compound when the halogenated hydrocarbon is reacted with metallic magnesium can be used. The amount of the ester of formula (I) left in the catalyst differs according to the preparation process, but the titanium/magnesium/ester molar ratio is preferably in the range of 1/(1 to 1,000)/(10⁻⁶ to 100), more preferably 1/(2 to 100)/(10⁻⁴ to 10). If the amount of the ester of formula (I) is too small, the stereospecificity of the olefin polymer is reduced, but if the amount of the ester of formula (I) is too large, the catalytic activity is reduced. The polymerization of olefins will now be described. An olefin can be polymerized by using the thus-obtained solid catalyst component of the present invention in combination with an organic aluminum compound. As typical examples of the organic aluminum compound used in the present invention, there can be mentioned compounds represented by the following general formulae (III) through (V): AlR⁹R¹⁰R¹¹ (III) R¹²R¹³Al-O-AlR¹⁴R¹⁵ (IV) and In formulae (III) through (V), R⁹, R¹⁰ and R¹¹, which may be the same or different, represent a hydrocarbon group having up to 12 carbon atoms, a halogen atom or a hydrogen atom, with the proviso that at least one of R⁹, R¹⁰ and R¹¹ represents a hydrocarbon group, R¹², R¹³, R¹⁴, and R¹⁵, which may be the same or different, represent a hydrocarbon group having up to 12 carbon atoms, R¹⁶ represents a hydrocarbon group having up to 12 carbon atoms, and ℓ is an integer of at least 1. As typical examples of the organic aluminum compound represented by formula (III), there can be mentioned trialkylaluminum compounds such as triethylaluminum, tripropylaluminum, tributylaluminum, trihexylaluminum and trioctylaluminum, alkylaluminum hydrides such as diethylaluminum hydride and diisobutylaluminum hydride, and alkylaluminum halides such as diethylaluminum chloride, diethylaluminum bromide, and ethylaluminum sesquichloride. As typical examples of the organic aluminum compound represented by formula (IV), there can be mentioned alkyldialumoxanes such as tetraethyldialumoxane and tetrabutyldialumoxane. Formula (V) represents an aluminoxane, which is a polymer of an aluminum compound. R¹⁶ includes methyl, ethyl, propyl, butyl, and pentyl groups, but methy and ethyl groups are preferable. Preferably, 2 is from 1 to 10. Among these organic aluminum compounds, trialkylaluminum compounds, alkylaluminum hydrides and alkylalumoxanes are preferably used, and trialkylaluminum compounds are especially preferably used because they give especially good results. In the polymerization reaction of α-olefins having at least 3 carbon atoms, to improve the stereoregularity of formed polymers, various compounds having a stereo-regularity-improving effect, use of which has been proposed for Ziegler catalysts, can be added to a catalyst system comprising the titanium-containing solid catalyst component of the present invention and a catalyst component comprising an organic aluminum compound. As the compound used for this purpose, there can be mentioned aromatic monocarboxylic acid esters, silicon compounds having an Si-O-C or Si-N-C bond, acetal compounds, germanium compounds having a Ge-O-C bond and nitrogen- or oxygen-containing heterocyclic compounds having an alkyl substituent. As specific examples, there can be mentioned ethyl benzoate, butyl benzoate, ethyl p-toluylate, ethyl p-anisate, phenyltrimethoxysilane, phenyltriethoxysilane, diphenyldimethoxysilane, diphenyldiethoxysilane, di-n-propyldimethoxysilane, cyclohexylmethyldimethoxysilane, tetraethylsilane, t-butylmethyldimethoxysilane, benzophenonedimethylacetal, benzophenonediethylacetal, acetophenone dimethylacetal, t-butylmethylketone-dimethyl-acetal, diphenyldimethoxygerman, phenyltriethoxygerman, 2,2,6,6-tetramethylpiperidine and 2,2,6,6-tetramethylpyrane. Among these compounds, silicon compounds having an Si-O-C or Si-N-C bond and acetal compounds are preferably used, and silicon compounds having on Si-O-C bond are especially preferably used. In the polymerization of olefins, the amount of the organic aluminum compound in the polymerization system is generally at least 10⁻⁴ millimole/ℓ and preferably at least 10⁻² millimole/ℓ. The molar ratio of the organic aluminum compound to the titanium atom in the solid catalyst component is generally at least 0.5, preferably at least 2 and more preferably at least 10. If the amount of the organic aluminum compound is too small, the polymerization activity is drastically reduced. If the amount of the organic aluminum compound used is larger than 20 millimoles/ℓ and the molar ratio to the titanium atom is higher than 1,000, the catalyst performances are not further increased even by increasing these values. When the titanium-containing solid catalyst component of the present invention is used, even if the amount of the above-mentioned stereoregularity-improving agent used for improving the stereoregularity of an α-olefin polymer is very small, the intended object can be attained. This agent is generally used, however, in an amount such that the molar ratio to the organic aluminum compound is 0.001 to 5, preferably 0.01 to 1. In general, olefins having 2 to 18 carbon atoms are used. As typical instances, there can be mentioned ethylene, propylene, butene-1, 4-methylpentene-1, hexene-1 and octene-1. These olefins can be homopolymerized, or two or more of these olefins can be copolymerized a typical example is copolymerization of ethylene with propylene. In carrying out the polymerization, the solid catalyst component of the present invention, the organic aluminum compound and optionally, the stereoregularity-improving agent can be independently introduced into a polymerization vessel, or two or more of them can be premixed. The polymerization can be carried out in an inert solvent, a liquid olefin monomer or a gas phase. To obtain a polymer having a practically adoptable melt flow rate, a molecular weight modifier (ordinarily, hydrogen) can be made present in the polymerization system. The polymerization temperature is preferably -10 to 180°C and more preferably 20 to 130°C. The shape of the polymerization vessel, the polymerization controlling procedure and the post-treatment procedure are not particularly limited in the present invention, and known procedures can be adopted. The present invention will now be described in detail with reference to the following examples that by no means limit the scope of the invention. In the examples and comparative examples, the heptane index (H.R.) means the amount (%) of the residue obtained when the obtained polymer was extracted with boiling n-heptane for 6-hours. The melt flow rate (MFR) was measured with respect to the polymer powder containing 0.2% of 2,6-di-tert-butyl-4-methylphenol incorporated therein at a temperature of 230°C under a load of 2.16 kg according ot JIS K-6758. In the examples, all of the compounds (organic solvents, olefins, hydrogen, titanium compounds, magnesium compounds, stereoregularity-improving agents) used for the preparation of the solid catalyst component and the polymerization were in the substantially anhydrous state. The preparation of the solid catalyst component and the polymerization were carried out in a substantially anhydrous nitrogen atmosphere. Example 1 Preparation of Solid Catalyst Component A stainless steel cylindrical vessel having an inner volume of 1 liter, in which magnetic balls having a diameter of 10 mm were filled in an amount of about 50% based on the apparent volume, was charged with 20 g (0.21 mole) of anhydrous magnesium chloride (obtained by heating to dry commercially available anhydrous magnesium chloride at about 500°C for 15 hours in a dry hydrogen chloride gas), 11.1 g (0.05 mole) of ethyl 3-ethoxy-2-phenylpropionate, 3.3 ml of titanium tetrachloride and 3.0 ml of a silicone oil (TSS-451.20CS supplied by Shin-Etsu Chemical) as the pulverizing assistant in a dry nitrogen current. The vessel was attached to a shaking ball mill having an amplitude of 6 mm and the co-pulverization was carried out for 15 hours to obtain a co-pulverized solid. Then, 15 g of the co-pulverized solid was suspended in 150 ml of 1,2-dichloroethane, and the suspension was stirred at 80°C for 2 hours. The solid was recovered by filtration and thoroughly washed with hexane until free 1,2-dichloroethane was not detected in the washing liquid. The solid was dried at a low temperature to 30 to 40°C under a reduced pressure to remove hexane, whereby a solid catalyst component was obtained. The titanium atom content in the solid catalyst component was 2.3% by weight. Polymerization and Physical Properties of Polymer A stainless steel autocrave having an inner volume of 3 ℓ was charged with 20 mg of the solid catalyst component prepared by the above-mentioned method, 91 mg of triethylaluminum and 20 mg of diphenyldimethoxysilane, and immediately, 760 g of propylene and 0.1 g of hydrogen were charged into the autocrave. The inner temperature of the autocrave was elevated and maintained at 70°C. After 1 hour, the gas in the autocrave was discharged to stop the polymerization. As the result, 314 g of powdery polypropylene was obtained. The polymerization activity was thus 15,700 g/g of solid catalyst component·hour and 683 kg/g of Ti·hour. The H.R. of the powdery polypropylene was 95.9%, and the MRF was 8.6 g/10 min. Example 2 Using the solid catalyst component prepared in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that the polymerization temperature was changed to 80°C. As the result, 408 g of a powdery polymer was obtained. The polymerization activity was 20,400 g/g of solid catalyst component·hr and 887 kg/g of Ti·hour, the H.R. of the powdery polypropylene was 97.1%, and the MFR was 3.4 g/10 min. Example 3 Using the solid catalyst component used in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that 20 mg of phenyltriethoxysilane was used at the polymerization instead of diphenyldimethoxysilane. The polymerization activity was 14,300 g/g of solid catalyst component·hr and 622 kg/g of Ti·hr, the H.R. of the obtained polymer was 95.8%, and the MFR was 12.3 g/10 min. Examples 4 through 7 Using the solid catalyst component used in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that the stereoregularity-improving agent added was changed as shown in Table 1. The results are shown in Table 1. Example 8 In a round-bottom flask, 9.5 g of anhydrous magnesium chloride (treated in the same manner as described in Example 1) was heated and dissolved at 130°C for 2 hours in 50 ml of decane and 46.8 ml of 2-ethylhexyl alcohol in on N₂ atmosphere. Then, 2.1 g of phthalic anhydride was added to the mixture, and the mixture was heated it 130°C for 1 hour. The liquid mixture was cooled to room temperature and 20 ml of the liquid mixture was charged in a dropping funnel and dropped into 80 ml of titanium tetrachloride maintained at -20°C over a period of 30 minutes. The temperature was elevated to 110°C over a period of 4 hours, and a solution of 3.3 g of ethyl 3-ethoxy-2-phenylpropionate was gradually dropped into the reaction mixture. After termination of the dropwise addition, the reaction was carried out at 100°C for 2 hours. The supernatant was removed, 80 ml of TiCl₄ was added to the residue, and the mixture was heated at 110°C for 2 hours. Then, the formed solid was washed with 100 ml of n-decane three times and then with n-hexane to obtain a solid catalyst in which the amount of Ti supported was 2.8% by weight. Using the thus-obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. The polymerization activity was 12,600 g/g of solid catalyst·hr and 450 kg/g of Ti·h, the H.R. was 95.7%, and the MFR was 2.0 g/10 min. Example 9 A round-bottom flask having a capacity of 300 ml, which was sufficiently dried in a nitrogen current, was charged with 100 ml of n-heptane, 9.5 g of MgCl₂ and 68 g of Ti(O-nB) and the reaction was carried out at 100°C for 2 hours to form a homogeneous solution. After termination of the reaction, the temperature was lowered to 40°C and 15 ml of methylhydrogen polysiloxane 2 x 10⁻⁵ m²/s (20 cSt) was added to the solution, and the reaction was carried out for 3 hours. The formed solid catalyst was washed with n-heptane, 150 ml of heptane was added to the solid catalyst, and a solution of 28 g of SiCl₄ in 80 ml of n-heptane was dropped at room temperature over a period of 1 hour. After termination of the dropwise addition, the reaction was further conducted for 30 minutes. The obtained solid component was washed with 200 ml of n-heptane three times and cooled to -10°C. Then, 100 ml of TiCl₄ was introduced into the solid, the resulting mixture was thoroughly stirred, and 2.82 g of ethyl 3-ethoxy-2-phenylpropionate was added dropwise to the mixture. After termination of the dropwise addition, the reaction was carried out at 90°C for 2 hours. The supernatant was removed, 100 ml of TiCl₄ was introduced, and the reaction was carried out at 90°C for 2 hours. After the reaction, the formed solid was washed with n-heptane to obtain a solid catalyst. From the results of the analysis, it was found that the amount of Ti supported was 2.4% by weight. Using the thus-obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. The polymerization activity was 12,900 g/g of solid catalyst·hr and 538 kg/g of Ti·h, the H.R. was 95.0%, and the MFR was 23 g/10 min. Example 10 A round-bottom flask having a capacity of 300 ml, which gas sufficiently dried in a nitrogen current, was charged with 5 g of magnesium diethoxide, 1.22 g of ethyl 3-ethoxy-2-phenylpropionate and 25 ml of methylene chloride, and the mixture was stirred under reflux for 1 hour. The formed suspension was introduced under pressure into 200 ml of TiCl₄ maintained at room temperature, the temperature of the mixture was gradually elevated to 110°C, and the reaction was carried out with stirring for 2 hours. After termination of the reaction, the precipitated solid was recovered by filtration and washed with 200 ml of n-decane maintained at 110°C three times. Then, 200 ml of TiCl₄ was added to the solid and the reaction was carried out at 120°C for 2 hours. After termination of the reaction, the precipitated solid was recovered by filtration, washed with 200 ml of n-decane maintained at 110°C three times and then washed with hexane until the chlorine ion was not detected. The content of the titanium atom in the obtained catalyst component was 3.2%. Using the thus-obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. When the calculation was made from the results, it was found that the polymerization activity was 20,800 g/g of solid catalyst component·hr and 650 kg/g of Ti·h, the H.R. was 96.8%, and the MFR was 1.7 g/min. Examples 11 through 21 Solid catalyst components were prepared in the same manner as described in Example 10 except that ester compounds shown in Table 2 were used instead of ethyl 3-ethoxy-2-phenylpropionate. Using the thus-prepared solid catalyst components, the polymerization was carried out in the same manner as described in Example 1. The results are shown in Table 2. Comparative Examples 1 through 4 Solid catalyst components were prepared in the same manner as described in Example 10 except that the esters shown in Table 3 were used instead of ethyl 3-ethoxy-2-phenylpropionate used in Example 10. Using these solid catalyst components, the polymerization was carried out in the same manner as described in Example 1. The results are shown in Table 3. Example 22 Using the solid catalyst component used in Example 1, the polymerization was carried out in the same manner as described in Example 1 except that diphenyldimethoxysilane was not used. It was found the polymerization activity was 17,300 g/g of solid catalyst component·hr and 752 kg/g of Ti·h, the H.R. of the obtained polypropylene powder was 51.3%, and the MFR thereof was 15.1 g/10 min. Comparative Example 5 A solid catalyst was prepared in the same manner as described in Example 1 except that ethyl 3-ethoxy-2-phenylpropionate was not used. Using the obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1 except that diphenyldimethoxysilane was not used. It was found that the polymerization activity was 9,110 g/g of solid catalyst component·hr and 285 kg/g of Ti·h, the H.R. of the obtained polypropylene powder was 23.7%, and the MFR thereof was 7.9 g/10 min. Comparative Example 6 A solid catalyst was prepared in the same manner as described in Example 1 except that ethyl 3-ethoxy-2-phenylpropionate was not used. Using the obtained solid catalyst component, the polymerization was carried out in the same manner as described in Example 1. It was found that the polymerization activity was 4,910 g/g of solid catalyst component·hr and 213 kg/g of Ti·h, the H.R. of the obtained polypropylene powder was 71.2%, and the MFR thereof was 3.8 g/10 min. When olefins are polymerized by using the catalyst component of the present invention, since the catalyst has a very high activity, the content of the catalyst residue in the formed polymer can be reduced to a very low level and therefore, the ash-removing step can be omitted. Furthermore, since the amount (concentration) of the residual halogen is small, the degree of corrosion of a molding machine or other apparatuses at the polymer-processing step can be greatly lowered. The deterioration and yellowing of the polymer caused by the residual catalyst can be minimized. Moreover, since the obtained polymer has a high stereoregularity, a polymer having a practically acceptable mechanical strength can be obtained even without removing an atactic portion.

Claims: A catalyst component for use in the polymerization of olefins, which contains magnesium, titanium, a halogen, and an ingredient derived from at least one member selected from the group consisting of esters represented by the following formula (I) (R¹O) i (R²O) j (R³O) k -Z-COOR⁴ (I) wherein R¹, R², R³ and R⁴ independently represent an aliphatic hydrocarbon group, an alicyclic hydrocarbon group, an aromatic hydrocarbon group, a polycyclic hydrocarbon group, or a heterocyclic compound group, Z represents an aliphatic or alicyclic hydrocarbon group in which a hydrogen atom may be substituted with an aromatic group or a polycyclic group, and i, j and k are integers of from 0 to 3 with the proviso that the sum of i, j and k is at least 1, wherein said titanium, magnesium and ester of formula (I) are present at a molar ratio of 1:1-1,000:10⁻⁶-100. The catalyst component according to claim 1, wherein the ester of formula (I) is an alkoxy ester represented by the following formula (II): wherein R⁵ and R⁶ independently represent an aliphatic hydrocarbon group having 1 to 20 carbon atoms, R⁷ and R⁸ independently represent a hydrogen atom or an aliphatic hydrocarbon group having 1 to 20 carbon atoms, Y represents a divalent linear hydrocarbon group having 1 to 4 carbon atoms, which is substituted with an aliphatic hydrocarbon group having 1 to 18 carbon atoms, an aromatic hydrocarbon group having 6 to 18 carbon atoms, or a polycylic hydrocarbon group having 6 to 18 carbon atoms, or a divalent alicyclic hydrocarbon group having 3 to 12 carbon atoms. The catalyst component according to claim 1 or 2, which contains titanium, magnesium, and the ingredient derived from the ester of formula (I) at a molar ratio of 1:2-100:10⁻⁴-10, respectively. A catalyst composition for use in the polymerization of olefins, which comprises (a) the catalyst component according to any of the claims 1 to 3 and (b) an organic aluminum compound: said organic aluminum compound being selected from the group consisting of the compounds represented by the following general formulae (III) through (V): AlR⁹R¹⁰R¹¹ (III) R¹²R¹³Al-O-AlR¹⁴R¹⁵ (IV) and wherein R⁹, R¹⁰, and R¹¹ independently represent a hydrocarbon group having up to 12 carbon atoms, a halogen atom or a hydrogen atom, with the proviso that at least one of R⁹, R¹⁰ and R¹¹ represents a hydrocarbon group, R¹², R¹³, R¹⁴, and R¹⁵ independently represent a hydrocarbon group having up to 12 carbon atoms, R¹⁶ represents a hydrocarbon group having up to 12 carbon atoms, and ℓ is an integer of at least 1, wherein the amount of the organic aluminum compound is 0.5 to 1,000 moles per mole of titanium being present in said component (a). A process for the preparation of the catalyst component according to any of the claims 1 to 3 which comprises forming a solid catalyst component comprising magnesium, titanium and a halogen as indispensable ingredients and treating the solid catalyst component during or after its formation with at least one member selected from the group consisting of esters represented by the formula (I) or (II) as defined in claim 1 or 2, wherein the amounts of the magnesium compound, the titanium compound, and the ester of formula (I) are such that the resulting catalyst component contains titanium, magnesium, and the ester of formula (I) at a molar ratio of 1:1-1,000:10⁻⁶-100, respectively, more preferably at a molar ratio of 1:2-100:10⁻⁴-10, respectively. The process according to claim 5, wherein the solid catalyst component to be treated with the ester of formula (I) is prepared from a magnesium compound, a titanium compound, and a halogen-containing compound which may be the same as the magnesium compound or the titanium compound. The process according to claim 6, wherein the magnesium compound is magnesium halide and the titanium compound is titanium tetrahalide. A process for polymerizing an olefin which comprises contacting an olefin having 2 to 18 carbon atoms with the catalyst composition claimed in claim 4, wherein the amount of the catalyst composition used is such that the amount of the organic aluminum compound is 10⁻⁴ to 20 millimoles per liter of the polymerization system. The polymerization process according to claim 8, wherein the catalyst composition further comprises 0.001 to 5 moles, per mole of the organic aluminum compound, of a stereoregularity-improving agent selected from the group consisting of aromatic monocarboxylic acid esters, silicon compounds having an Si-O-C or Si-N-C bond, acetal compounds, germanium compounds having a Ge-O-C bond, and nitrogen- or oxygen-containing heterocyclic compounds having an alkyl substituent. The polymerization process according to claim 8 or 9, wherein the polymerization is carried out at a temperature of -10°C to 180°C.

Inventors: FUSHIMI MASAKI C O SHOWA DENKO, MIYAKE SHIGENOBU C O SHOWA DEN, NAKAJO TETUO C O SHOWA DENKO K, SAKURAI HIDEKI, FUSHIMI, MASAKI, C/O SHOWA DENKO K.K., MIYAKE, SHIGENOBU, C/O SHOWA DENKO K.K., NAKAJO, TETUO, C/O SHOWA DENKO K.K., SAKURAI, HIDEKI
Applicants: SHOWA DENKO KK, SHOWA DENKO KABUSHIKI KAISHA
Application year: 1990
Main classification: C08F4
IPC codes: C08F4, C08F10