Olefin polymerization catalyst

Abstract: A high activity olefin polymerization catalyst, useful in the polymerization of low α-olefins, is obtainable by contacting an alkylaluminum halide with a solid reaction product of a magnesium alkoxide, a titanium tetraalkoxide and a phenolic compound which is phenol or an activated phenol and may be used to prepare olefin polymers by polymerizing at least one α-olefin, optionally in conjunction with a selectivity control agent.

Description: This invention relates to a high activity olefin polymerization catalyst and to a process for the polymerization of olefins in the presence of that catalyst. The production of homopolymers and copolymers of lower α-olefins is of substantial commercial importance. The polymeric products are inexpensive and have commercially useful properties. Polymerization of ethylene is relatively uncomplicated in that the product type is not influenced by the manner in which the ethylene molecules add to the growing chain. Polypropylene provides the possibility of several product types depending on the stereoregularity with which the propylene molecules add to the growing chain. Much of the polypropylene produced commercially is crystalline and results from the addition of propylene molecules in a stereoregular head-to-tail manner. The form of polypropylene having a substantial proportion of random addition is termed atactic and this amorphous form of the polymer is less desirable. The atactic polypropylene must be removed as by an extraction process to provide more desirable crystalline material. Also significant is the activity of the polymerization catalyst. Early trivalent titanium, chromium or vanadium catalysts were of relatively low activity and the polymeric product contained significant amounts of catalyst residues. The removal of such residues as by a deashing step was required. Recent titanium, and particularly tetravalent titanium, polymerization catalysts are more stereoregulating and active so that extraction and deashing steps are not required. In terms now employed conventionally, the high activity olefin polymerization catalysts are formed from a solid catalyst component, often termed a procatalyst, which typically contains magnesium, titanium and halide moieties, a cocatalyst which is usually an organoaluminum compound and a selectivity control agent (SCA). Although each of these three components has a significant influence on the catalyst process and polymeric product, the nature of the catalyst and the polymeric product appear to be most influenced by the procatalyst. Many procatalyst species are obtained by treatment of a magnesium compound with tetravalent titanium halide, often in the presence of a halohydrocarbon and an electron donor. US-A-4,330,649 describes a solid catalyst component obtained by heating a soluble magnesium compound with a higher alcohol in the presence of an ester to produce a solution. To this solution is added TiCl 4 and an electron donor (ED) to form the procatalyst. US-A-4,472,521 describes reacting a magnesium alkoxide with a titanium alkoxide in the presence of an aromatic hydrocarbon. TiCl 4 and an ED are added to the resulting solution to form a solid procatalyst which is then post-treated with a transition metal halide. US-A-4,540,679 describes the production of an olefin polymerization catalyst component by contacting a suspension of Mg(OC 2 H 5 ) 2 in ethanol with CO 2 . The addition of an organoaluminum compound in a hydrocarbon results in the production of particles which are employed as support for a titanium compound upon contact of the particles with TiCl 4 . US-A-4,728,705 describes solubilizing magnesium ethoxide in ethanol with CO 2 and spray drying the resulting solution or using the solution to impregnate carrier particles. The particles are contacted with TiCl 4 to form a procatalyst. A somewhat different process is described in US-A-4,710,428, wherein a magnesium compound of the general formula Mg 4 (OR) 6 (ROH) 10 A is formed wherein R is alkyl of up to 4 carbon atoms and A is at least one anion having a total oxidation state of -2. This complex is contacted with a tetravalent titanium halide, a halohydrocarbon and an ED to form the procatalyst. Olefin polymerization procatalyst precursors have been produced which contain titanium moieties as well as magnesium moieties. In EP-A-0 481 792 we describe the production of a complex having the general stoichiometry of Mg 3 Ti(OR) 8 X 2 wherein each R is alkyl of up to 4 carbon atoms and X is an anion derived from a phenolic compound. Such complex alkoxides are produced from a magnesium alkoxide, a titanium tetraalkoxide and the phenolic compound in alkanolic solvent. Alkanol is removed from a solution of this product is hydrocarbon or halohydrocarbon to provide a clear solution. A solid procatalyst is produced by the addition of a tetravalent titanium halide and an ED to the solution. The procatalyst is then converted to a polymerization catalyst by contacting with an organoaluminum compound and a SCA. This catalyst is an effective high activity olefin polymerization catalyst and provides polymeric product having good properties in high yield (high catalyst productivity). However, it would be of advantage to provide a simplified method of producing such an olefin polymerization catalyst. The present invention provides an olefin polymerization catalyst obtainable by contacting an alkylaluminum halide with a solid reaction product of a magnesium alkoxide, a titanium tetraalkoxide and a phenolic compound which is phenol or monohydroxylic phenol of one aromatic ring having at least one ring substituent which is not hydroxy or formyl which is free from active hydrogen atoms and which alters the pKa of the phenolic compound, wherein the solid reaction product is not obtained using a halide of tetravalent titanium. The solid reaction product is preferably of the formula (II) set out above. The resulting solid olefin polymerization catalyst can be employed, together with an SCA, in preparing α-olefin polymers by the polymerization of at least one α-olefin, such as ethylene or propylene, in the presence of the catalyst. The α-olefin polymers are produced with relatively high catalyst productivity and have good properties. The present invention thus contemplates the formation of an olefin polymerization catalyst by contacting an alkylaluminum halide halogenating agent with a complex magnesium-containing, titanium-containing, alkoxide compound prepared by reaction of a magnesium alkoxide, a titanium tetraalkoxide and a phenolic compound in an inert diluent. The diluent is then removed to produce the complex alkoxide compound. This solid is treated with alkylaluminum halide to produce the olefin polymerization catalyst. This catalyst is used, in the optional presence of SCA, to polymerize lower α-olefins by polymerization techniques which are largely conventional. The alkoxide moieties of the magnesium alkoxide can be the same as or different from the alkoxide moieties of the titanium tetraalkoxide. Preferably all the alkoxide moieties of both metal alkoxides are the same. The preferred alkoxide moieties are methoxide or ethoxide and particularly preferred is ethoxide. Mg(OC 2 H 5 ) 2 and Ti(OC 2 H 5 ) 4 are the preferred metal alkoxide reactants. The phenolic compound used as reactant is phenol or an activated phenol. By the term "activated phenol" is meant a monohydroxylic phenol of one aromatic ring having at least one aromatic ring substituent other than hydrogen, hydroxy or formyl which serves to alter the pKa of the phenolic compound. Such substituent groups are free from active hydrogen atoms and include halogen, e.g. chlorine or bromine, alkyl of up to 4 carbon atoms, and dialkylamino wherein each alkyl has up to 4 carbon atoms. Illustrative of suitable phenolic compounds are phenol, o-cresol, 3-methoxyphenol, 2,6-di-t-butyl-4-methylphenol (BHT), 2,4-diethylphenol, p-chlorophenol, p-bromophenol, 2,4-dichlorophenol and p-dimethylaminophenol. The contacting of the magnesium alkoxide, titanium tetraalkoxide and phenolic compound takes place at an elevated temperature in an inert diluent. The reaction diluent is one in which all reactants are at least partially soluble and which does not react with the reactants or the complex alkoxide product. Preferred reaction diluents are hydrocarbons such as isooctane or isopentane, or are halohydrocarbons such as methylene chloride, carbon tetrachloride or chlorobenzene. The contacting suitably takes place at a temperature from 50°C to 90°C. Contacting is effected in a suitable reactor and can be facilitated by conventional procedures such as shaking, stirring or refluxing. The phenolic compound is suitably provided in a quantity of from 0.1 mole to 4 moles per mole of titanium tetraalkoxide but preferably in a quantity of from 0.5 mole to 2 moles per mole of titanium. The magnesium alkoxide is suitably provided in a quantity from 1.5 mole to 8 moles per mole of titanium tetraalkoxide, preferably from 3 moles to 6 moles per mole of titanium alkoxide. The product of contacting the magnesium alkoxide, the titanium tetraalkoxide and phenolic compound in the inert reaction diluent is a solution of the complex alkoxide compound in the diluent. To obtain the solid complex alkoxide compound, the complex alkoxide compound is separated from the diluent. In one modification, a non-solvent is added to precipitate the complex alkoxide compound which is then recovered as by filtration. In a preferred modification, however, the reaction diluent is removed as by distillation or evaporation. In a modification of solvent removal by distillation, a cosolvent is added which forms an azeotrope with the reaction diluent and the distillation is azeotropic. In a second and preferred modification of removal by distillation, the reaction diluent is removed by a simple distillation at or below atmospheric pressure. The solid product resulting from either modification is a complex alkoxide compound useful in preparing an olefin polymerization catalyst. The conversion of the complex alkoxide compound to the olefin polymerization catalyst is by treatment with alkylaluminum halide. Suitable alkylaluminum halides have 1 or 2 alkyl groups independently of up to 8, preferably up to 4, carbon atoms and 2 or 1 halide moieties. Preferred alkylaluminum halides are of R′ n AlY 3-n wherein each R′ is alkyl of up to 4 carbon atoms, Y is chlorine or bromine and n is 1 or 2. Illustrative of such alkylaluminum halides are ethylaluminum dichloride, diethylaluminum chloride, diethylaluminum bromide and methylaluminum dibromide. The compounds of formula III wherein n is 2 are preferred as are the compounds wherein R is ethyl. Particularly preferred as alkylaluminum halide is ethylaluminum dichloride. The reaction of the solid complex alkoxide compound with the alkylaluminum halide is conducted by contacting the reactants. If liquid, a preferred method of contacting is by mixing the alkylaluminum halide and the complex alkoxide compound at an elevated temperature. Suitable contacting temperatures are from 20°C to 100°C, but preferably from 35°C to 90°C. To ensure adequate contacting a diluent such as a hydrocarbon or halohydrocarbon may be used but in other modifications, no diluent is present during the contacting. Subsequent to the contacting, the resulting solid is typically washed with a light hydrocarbon, e.g. isooctane, to remove unreacted materials. The resulting solid is useful as such as an olefin polymerization catalyst. The alkylaluminum halide is suitably provided in an amount of from 1 mole to 150 moles, preferably from 10 moles to 30 moles, per mole of titanium of the complex alkoxide compound. The olefin polymerization catalyst is utilized in the presence or in the absence of an SCA. A suitable SCA, when employed, can be an SCA conventionally employed with olefin polymerization catalysts based on titanium and aluminum. The SCA suitably is a compound free from active hydrogen atoms, e.g. esters, ethers, amines, imines, nitriles, phosphines, arsines, stibines and silanes. The preferred selectivity control agents are esters, particularly alkyl esters of aromatic monocarboxylic or dicarboxylic acids, or are alkylalkoxysilanes of the formula R″ n Si(OR) 4-n wherein R″ is cycloalkyl or alkyl of up to 8 carbon atoms, and R and n are as previously defined. Illustrative of preferred selectivity control agents are, as esters, ethyl benzoate, ethyl p-ethoxybenzoate, diisobutyl phthalate and dimethyl naphthalenedicarboxtlate and, as alkylalkoxysilanes, diisobutyldimethoxysilane, isopropyltrimethoxysilane and cyclohexylmethyldimethoxysilane. When no selectivity control agent is employed, the catalyst as produced above is added directly to the polymerization zone in which polymerization takes place. Where the catalyst is utilized in conjunction with an SCA, the catalyst and SCA can be added separately or can be mixed prior to introduction to the polymerization zone. When the catalyst and SCA are premixed it is often useful to heat the resulting mixture to a temperature at or about polymerization temperature prior to introduction into the reaction zone. The olefin polymerization catalyst as produced is useful in the polymerization of lower α-olefins under polymerization conditions and particularly useful in the polymerization of straight-chain α-olefins of up to 4 carbon atoms, i.e. ethylene, propylene and 1-butene. The precise procedures of the polymerization process are broadly conventional but the olefin polymerization process of the invention provides olefin polymer product of good properties in good quantities. The polymerization product can be a homopolymer such as polyethylene or polypropylene when a single α-olefin monomer is supplied to the polymerization process or can be a copolymer such as ethylene-propylene rubber or polypropylene impact copolymer when two or even more α-olefin monomers are employed in the polymerization process. The nature of the desired polymer product will, however, influence the composition of the catalytic species. When the desired product is polyethylene or an ethylene copolymer or other product where stereoregularity of the product is not desired, an SCA is not typically provided. When a stereoregular product is required such as a crystalline polypropylene homopolymer it is preferred to provide the SCA to the polymerization mixture. During polymerization, up to 100 moles, preferably 0.5 to 25 moles, of SCA per mole of the titanium in the catalyst can be used. The polymerization process can be conducted as a gas-phase process employing one or more fluidized beds of catalyst or can be conducted as a slurry-phase process utilizing as diluent an inert material such as propane or other saturated hydrocarbon or alternatively a liquified monomer of the polymerization process such as propylene. The molecular weight of the polymer product and to some extent the properties of the polymer product are suitably influenced by the provision of the polymerization system of molecular hydrogen. The polymerization can be conducted in a batchwise manner or in a continuous or semi-continuous manner. The catalysts of the invention afford good yields of polyolefin product in the presence or absence of SCA. Where the olefin monomer is propylene or a higher α-olefin, the catalysts used in conjunction with the SCA exhibit relatively high productivity while retaining a desirably high stereospecificity. The activity and specificity of such catalyst systems are sufficiently high so that polymer is obtained in good yield with acceptable properties so that extraction and/or deashing steps are not required. The invention will be further illustrated by reference to the following Examples. In the Examples the productivity of the catalyst (yield) is determined in kilograms of product obtained per gram of catalyst or of titanium in the catalyst in a standard batch slurry-phase polymerization of one hour. When propylene is polymerised, the stereospecificity of the catalyst and specifically the stereospecificity to isotactic product is determined by measuring the xylene solubles (termed XS) in percent by weight of the polymer in accordance with the regulations of the U.S. Food and Drug Administration. The test for xylene solubles is conducted by dissolving a polymer sample in xylene under reflux in a flask. The flask is then maintained in a water bath at 25°C for 1 hour without stirring during which the xylene insoluble portion precipitates. The precipitate is removed by filtration and the solubles content is determined by evaporating an aliquot of the filtrate and drying and weighing the residue. The xylene solubles consist primarily of amorphous (atactic) polymer with a small amount of low molecular weight polymer. Example I - Procatalyst Precursors A. Mg(OC 2 H 5 ) 2 (116 g, 1.01 mol), Ti(OC 2 H 5 ) 4 (95%, 81.2 g, 0.34 mol) and o-cresol (73 g, 0.67 mole) were slurried in 276 g of isooctane in a 1-litre, 3-neck flask equipped with a reflux condenser. After stirring at 85°C for over 1 hour a clear, yellow, relatively non-viscous solution was obtained. The solution contained 4.5% magnesium. Into a crystallizing dish, 100 g of the solution was poured and the solvent was allowed to evaporate overnight under nitrogen. The resulting sticky solid was placed on an 80°C hotplate for 4 hours to remove the remaining solvent and the resulting solid was ground to give a yellow powder. The molar ratio of cresol to magnesium to titanium was 2/3/1. C. Mg(OC 2 H 5 ) 2 (11.6 g, 101 mmol), Ti(OC 2 H 5 ) 4 (95%, 8.12 g, 34 phenol) and o-cresol (7.3 g, 68 mmol) were slurried in 60 g of CH 2 Cl 2 in a closed 0.1 litre (4 oz) bottle and stirred for 2 days in a 58°C oil bath. The clear yellow solution was evaporated to dryness in a crystallizing dish under flowing nitrogen and the resulting solid was ground to give a yellow powder. The magnesium content was 12% by weight and the cresol/Mg/Ti molar ratio was 2/4/1. E. Mg(OC 2 H 5 ) 2 (11.6 g, 101 mmol), Ti(OC 2 H25) 4 (95%, 8.12 g, 34 mmol and 2,6-di-t-butyl-4-methylphenol, BHT, (14.9 g, 68 mmol) were slurried in 35 g of cyclohexane in a closed bottle. While this mixture was stirred in a 105°C oil bath, slow dissolution took place. After 36 hours, solid still remained and an additional 74 g of cyclohexane was added. The slurry was stirred at 105°C for an additional day and then cooled overnight. The mixture was then filtered to give a yellow solution and about 2.7 g of solid. The solvent was then removed by evaporation to give 9.5 g of orange-yellow powder. The molar ratio of BHT/Mg/Ti was 2/3/1. F. Mg(OC 2 H 5 ) 2 (11.6 g, 101 phenol), Ti(OC 2 H 5 ) 4 (95%, 8.12 g, 34 mmol, o-cresol (3.65 g, 34 mmol) and BHT (7.45 g, 34 phenol) were slurried in 50 g of cyclohexane in a closed 0.1 litre (4 oz) bottle. The mixture was stirred overnight in a 90°C oil bath to produce a clear, yellow solution. The solvent was removed by evaporation and the resulting solid was ground to a clear yellow powder. G. Mg(OC 2 H 5 ) 2 (11.6 g, 101 mmol), Ti(OC 2 H 5 ) 4 (95%, 9.12 g, 34 mmol) and 2,6-dimethylphenol were slurried in 50 g of isooctane in a closed 0.1 litre (4 oz) bottle and stirred for 4 hours in a 95°C oil bath to obtain a clear yellow solution. The solution was allowed to evaporate under flowing nitrogen to give a solid which was ground to a yellow powder. The 2,6-dimethylphenol/Mg/Ti molar ratio was 2/3/1. H. Mg(OC 2 H 5 ) 2 (11.6 g, 101 mmol), Ti(OC 2 H 5 ) 4 (95% 8.12 g, 34 mmol) and phenol (6.39 g, 68 phenol) were slurried in 50 g of cyclohexane in a closed 0.1 litre (4 oz) bottle and stirred for 4 hours in a 95°C oil bath to obtain a clear solution. The solution was allowed to evaporate to dryness under flowing nitrogen and the resulting solid was ground to a powder. The molar phenol/Mg/Ti ratio was 2/3/1. J. Mg(OCH 2 H 5 ) 2 (11.6 g, 101 mmol), Ti(OC 2 H 5 ) 4 (95%, 81.2 g, 34 mmol) and 2,6-dimethylphenol (8.26 g, 68 mmol) were slurried in 50 g of isopentane in a closed 0.1 litre (4 oz) bottle and stirred for 10 hours in a 53°C oil bath to obtain a clear solution with about 0.2 g of solid remaining. This same amount of solid remained after an additional 14 hours of stirring. The solution was decanted from the solid and allowed to evaporate under flowing nitrogen to give a pale yellow solid. Example II - Procatalyst Preparation Polyolefin polymerization procatalysts were produced from the procatalyst precursors of Example I by slurrying a quantity of the precursor and of diethylaluminum chloride (DEAC) (as a 20% or 25% by weight solution in heptane) in a 0.1 litre (4 oz) bottle. The mixture was originally yellow but turned pale green and finally dark upon warming to about 40°C in an oil bath. After 30 minutes of warming, the slurry was filtered and the solids obtained were washed twice with isooctane and dried under flowing nitrogen to provide procatalyst as a free flowing, red-brown powder. In an alternative method using ethylaluminum dichloride, EADC, a precursor of Example I and the DEAC (as a 20% by weight solution in heptane) were slurried in a 0.1 litre (4 oz) bottle. The bottle and contents were placed in an 80°C oil bath and shaken and vented over about 10 minutes. The slurry was then filtered and the solids obtained were washed with isooctane and dried under flowing nitrogen to yield procatalyst as a brick-brown powder. Procatalysts prepared by these procedures are listed in Table I with the quantities of reactants and an indication of when the alkylaluminum halide was heated before mixing with the procatalyst precursor. The results of an elemental analysis for each procatalyst are also listed. Run No. Quantities of Precursor and Organoaluminium Compound Elemental Analysis, % wt. Ti Mg Cl Al 1 4g of A, 30g 25% DEAC (Hot) 7.5 11.9 49.5 3.8 2 4g of A, 60g 20% DEAC (Hot) 9.2 14.7 53.9 4.9 3 4g of A, 30g of EADC 6.0 14.9 - 5.6 4 4g of A, 30g of EADC (Hot) 7.9 12.8 61.1 4.5 5 4g of A,2x30g of 20% DEAC (Hot) 7.5 12.4 51.6 4.2 6 8g C, 60g of 20% DEAC (Hot) 7.5 12.7 51.0 3.4 7 4g A, 2x30g 20% EADC 8.1 12.6 63.8 5.2 8 4g E, 30g, 20% EADC (Hot) 3.5 15.5 55.7 4.4 9 4g F, 30g, 20% EADC (Hot) 5.8 13.9 59.7 3.4 10 4g G, 30g, 20% EADC (Hot) 8.0 12.2 61.5 4.4 11 4g H, 30g, 20% EADC (Hot) 6.9 11.4 57.3 4.4 12 4g J, 30g, 20% EADC (Hot) 8.0 13.0 56.2 5.0 Example III In a number of polymerizations, the procatalysts of Example II were employed as 5% by weight slurries in mineral oil. Triethylaluminum (TEA) was used as a 0.28 M solution in isooctane. The SCA was diisobutyldimethoxysilane (DIBDMS) except where otherwise stated and was used neat. In each polymerization, a mixture of 6.0 ml of TEA solution (1.68 mmol) and 60 µl of DIBDMS (0.32 mmol) were injected at 65°C into 2.7 liters of propylene in a 3.8 litre (one U.S. gallon) autoclave which also contained 42 mmol of hydrogen followed by 0.5 ml of the 5% procatalyst slurry (0.017 to 0.046 mmol Ti). Each polymerization was conducted at 65°C for 1 hour. The results are shown in Table II. Also shown are deviations, if any, from the above procedure. Procatalyst of Run No. Yield, Kg/g cat. X.S. % wt. Deviation 1 4.1 18.6 2 11.8 19.9 3 13.0 17.1 4 13.9 17.1 10.4 14.1 Procatalyst and SCA premixed 7.6 9.7 All components premixed 9.6 18.0 1:1 ratio TEA/SCA 6.9 23.4 no H 2 29.4 73.6 Al/Ti ratio about 5 11.2 64.6 Al/Ti ratio about 2 5 5.8 19.2 6 4.7 18.9 7 10.0 19.1 8 7.5 14.1 9 8.9 17.5 10 12.6 17.9 11 8.7 17.2 12 9.2 15.2 Example IV Using the same apparatus and cocatalyst amounts as for the propylene polymerization in Example III, the procatalyst of run 2, Example II, was injected into 1.0 litre of isooctane at 60°C into which ethylene gas was flowing at a rate of about 2.5 g/minute. After 125 g of ethylene had flowed, the reaction was terminated. The resulting slurry was filtered and the solids air dried to produce 125 g of free flowing, white granular polyethylene. Comparative Example DEAC (20 g of 20% heptane solution, 33 mmol) was diluted with 30 g of isooctane, then a solution prepared as in 'A' of Example I (6.26 g, 12.4 mmol Mg) was added dropwise to that stirring solution. The resulting tan colored slurry was filtered and the solids washed three times with warm isooctane and dried under moving nitrogen to yield a tan powder. A propylene polymerization, using this procatalyst, was carried out at 60°C as described in Example III to produce 0.1 kg of polymer/g of procatalyst. This represents an activity of only about 1% of the catalysts of this invention.

Claims: An olefin polymerization catalyst obtainable by contacting an alkylaluminum halide with a solid reaction product of a magnesium alkoxide, a titanium tetraalkoxide and a phenolic compound which is phenol or monohydroxylic phenol of one aromatic ring having at least one ring substituent other than hydroxy or formyl which is free from active hydrogen atoms and which alters the pKa of the phenolic compound, wherein the solid reaction product is not obtained using a halide of tetravalent titanium. A catalyst according to claim 1 wherein the alkylaluminum halide is of the formula R' n Al(Y) 3-n each R' is alkyl of up to 4 carbon atoms, Y is halogen and n is 1 or 2. A catalyst according to claim 2 wherein Y is chlorine and R' is ethyl. A catalyst according to claim 1, 2 or 3 wherein said solid reaction product is of the formula Mg 3 Ti(OR) 8 X 2 wherein each R is alkyl of up to 4 carbon atoms and each X is a monovalent anion of said phenolic compound. A catalyst according to claim 4 wherein X is the anion of o-cresol. A catalyst according to claim 4 or 5 wherein R is ethyl. A process for preparing an α-olefin polymer which comprises polymerizing at least one α-olefin in the presence of a polymerization catalyst as claimed in any one of the preceding claims. A process according to claim 7 wherein the catalyst is employed in conjunction with an olefin polymerization selectivity control agent.

Inventors: JOB ROBERT CHARLES, JOB, ROBERT CHARLES
Applicants: SHELL OIL CO, SHELL OIL COMPANY
Application year: 1992
Main classification: C08F10
IPC codes: C08F4, C08F10