Patent EA-004063-B1 (EA)
Title: Catalyst component comprising magnesium, titanium, a halogen and an electron donor, its preparation and use
Inventor: GAROFF THOMAS
IPC: C08F4/02
Filed: 1998-12-21
Abstract: 1. A process for the preparation of an olefin polymerization catalyst component containing magnesium, titanium, halogen and an electron donor, characterized by the steps of: reacting a titaniumless magnesium compound containing an alkoxy moiety, with halogen compound capable of forming the electron donor by replacement of its halogen by said alkoxy moiety, to give an intermediate, and reacting said intermediate with a titanium halide, wherein titaniumless magnesium compound is selected from the group consisting of a compound or complex containing halogen and alkoxide linked to magnesium, and a complex containing a magnesium dihalide and an alcohol, and a non-complex magnesium dialkoxide; reacting a titaniumless magnesium compound containing an alkoxy moiety, with titanium halide capable of forming the electron donor by replacement of its halogen by said alkoxy moiety, to give an intermediate, and reacting said intermediate with halogen compound, wherein titaniumless magnesium compound is selected from the group consisting of a compound or complex containing halogen and alkoxide linked to magnesium, and a complex containing a magnesium dihalide and an alcohol, wherein at least one of preferably first two steps and/or one of second two steps are carried out in solution. 2. A process according to claim1, characterized in that all reactions are carried out in solution. 3. A process according to claim 1 or 2, characterized in that the reaction product of said intermediate products with titanium halide or said halogen compound is recovered by precipitation. 4. A process according to claim1-3, characterized in that said titaniumless magnesium compound, halogen compound and titanium halide are contacted in essentially stoichiometric amounts or titanium halide or alternatively, that a stoichiometric excess, preferably a 5-20 fold stoichiometric excess with respect to said titaniumless magnesium compound, of said titanium halide is used. 5. A process according to claim1-4, characterized in that said magnesium dihalide is magnesium dichloride MgC12. 6. A process according to any of claims 1-5, characterized in that said halogen compound is an organic acid halide and preferably phthalic acid dichloride Ph(COCl)2, wherein Ph is o-phenylene, whereby the electron donors formed therefrom are, correspondingly, an organic acid ester and preferably a phthalic acid diester Ph(COOR)2, wherein R is C1-C20 alkyl or C7-C27 aralkyl, more preferably di-C6-C16 alkyl phthalate, most preferably dioctyl phthalate. 7. A process according to any of claims 1-6, characterized in that said titanium halide is a titanium tetrahalide, preferably titanium tetrachloride TiC14. 8. A process according to any of claims 1-7, characterized by the steps of : reacting said compound or complex containing halogen and alkoxide linked to magnesium as said titaniumless magnesium compound with said halogen compound to give an intermediate and reacting said intermediate (ab) with said titanium halide or: reacting said complex of said magnesium dihalide and said magnesium dialkoxide as said titaniumless magnesium compound with said titanium halide to give an intermediate and reacting said intermediate with said halogen compound. 9. A process according to claim 8, characterized in that said compound or complex containing halogen and alkoxide linked to magnesium as said titaniumless magnesium compound is a complex of a magnesium dihalide and a magnesium dialkoxide, preferably a magnesium dichloride and dimagnesium dialkoxide complex MgCl2' [Mg(OR)2]2, wherein R is C1-C20 alkyl or C7-C27 aralkyl, most preferably C6-C16 alkyl, which complex is preferably prepared by reacting magnesium dichloride MgCl2 with an alcohol ROH to give an intermediate and reacting the obtained intermediate with a dialkyl magnesium MgR"'2, wherein R"' is defined as for R. 10. A process according to claim 9, characterized in that reacting said magnesium dichloride and dimagnesium dialkoxide complex MgCl2'[Mg(OR)2]2, wherein R is C1-C20 alkyl or C7-C27 aralkyl, preferably C6-C16 alkyl, with said titanium halide, which is said titanium tetra chloride TiCl4, to give an intermediate and reacting said intermediate with said halogen compound, which is said phthalic acid dichloride Ph(COCl)2, wherein Ph is o-phenylene. 11. A process according to any of claims 1-7, characterized in that reacting titaniumless magnesium compound, which is said complex of said magnesium dihalide and said alcohol and said non complex magnesium dialkoxide, with said halogen compound to give an intermediate, which is a complex of said magnesium dihalide and said electron donor and reacting said intermediate, which is a complex of said magnesium dihalide and said electron donor with said titanium halide. 12. A process according to claim11, characterized in that, independently, said complex of said magnesium dihalide and said alcohol is a magnesium dichloride and alcohol complex MgCl2' (ROH)m, wherein R is C1-C20 alkyl or C7-C27 aralkyl, preferably C6-C16 alkyl, and m is 1-6, and said non-complex magnesium alkoxide is a magnesium dialkoxide Mg(OR)2, which is prepared by reacting magnesium dialkyl and alcohol ROH, wherein R is C1-C20 alkyl or C7-C27 aralkyl, preferably C6-C16 alkyl. 13. A process according to any of claims 1-7, characterized in that reacting said titaniumless magnesium compound, which is said complex of said magnesium dihalide and said alcohol, with said titanium halide to give an intermediate and reacting said intermediate with said halogen compound. 14. A process according to claim 13, characterized in that said complex of said magnesium dihalide and said alcohol compound is a magnesium dichloride and alcohol complex MgCl2' (ROH)m, wherein R is C1-C20 alkyl or C7-C27 aralkyl, preferably C6-C16 alkyl, and m is 1-6. 15. A process according to claim 14, characterized in that reacting said titaniumless magnesium compound, which is said magnesium dichloride and alcohol complex MgCl2' (ROH)m, wherein R is C1-C20 alkyl or C7-C27 aralkyl, preferably C6-C16 alkyl, and m is 1-6, with said titanium tetradihalide, which is said titanium tetrachlorideTiC14, to give an intermediate and reacting said intermediate with said halogen compound, which is said phthalic acid dichloride Ph(COCl)2, wherein Ph is o-phenylene. 16. A process according to any of claims 8-15, characterized in that said intermediate is added, preferably drop by drop, to said titanium halide, which is in liquid form and preferably hot, most preferably at 75-150 degree C. 17. A process according to any of claims 8-16, characterized in that the reaction product obtained by reacting of said intermediate product with titanium halide or said halogen compound is further treated with said titanium halide and/or washed, preferably repeatedly washed with an aromatic hydrocarbon, such as toluene, or an organic liquid having the same solubility parameter as said aromatic hydrocarbon. 18. A catalyst component comprising magnesium, titanium, a halogen and an electron donor, characterized in that it has been prepared by the process described in any of claims 1 to 17. 19. The catalyst component according to claim 18, characterized in that it is an isolated complex of a magnesium dihalide, preferably magnesium dichloride, an electron donor obtained by replacing the halogen of a halogen compound by an alkoxy group, preferably a phthalic acid diester, and a titanium halide, preferably titanium tetrachloride. 20. The catalyst component according to claim 19, characterized in that said complex has an X-ray pattern comprising a crystal height indicating peak between16 degree and 18 degree 2Theta obtained by Siemens D500 instrument, CuKa radiation wavelength 1.541A, effect 40 kV and 35 mA. 21. The catalyst component according to claim 18,19 or 20 characterized in that said complex is prepared by contacting stoichiometric amounts of said components. 22. The catalyst component according to any of claims 18-21 characterized in that said complex has an X-ray diffraction pattern comprising a peak between 5 and10 degree 2Theta obtained by Siemens D500 instrument, CuKa radiation wavelength 1.541A, effect 40 kV and 35mA. 23. The catalyst component according to any of claims 18-22 characterized in that noTiCl30R waste material is produced in the catalyst synthesis. 24. Use of a catalyst component according to any of claims 18-23 for the polymerization of alpha-olefines, preferably propylene. 25. Use according to claim 24, wherein, additionally, a catalyst component comprising an organometal compound of a metal belonging to Group1, 2 or 13 (IUPAC 1990) of the Periodic Table, preferably an alkyl aluminium compound, is used.