Patent EA-002145-B1 (EA)
Title: Process to prepare ziegler-natta catalyst for solution polymerization of a olefins mixture, a catalyst and process therefor
Inventor: JABER ISAM
IPC: C08F4/658
Filed: 1999-04-06
Abstract: 1. A process to prepare a catalyst for the solution polymerization of a mixture of one or more linear C2-12 alpha-olefins at a temperature from 105 degree C to 320 degree C and a pressure from 4 to 20 MPa wherein said catalyst comprises: (i) a mixture of an alkyl aluminum compound of the formula (R<1>)3Al<1> and (R<2>)2Mg wherein R<1> is a C1-10 alkyl radical and R<2> is a C1-10 alkyl radical in a molar ratio of Mg to Al<1> from 4.0:1 to 8:1; (ii) a halide of the formula R<3>X wherein R<3> is selected from the group consisting of C1-8 alkyl radicals and X is selected from the group consisting of chlorine and bromine; (iii) titanium tetrachloride; and (iv) an alkyl aluminum alkoxide compound of the formula (R<4>)2)Al<2>OR<5> wherein R<4> and R<5> are independently selected from the group consisting of C1-10 alkyl radicals, to provide a molar ratio of Mg:Ti from 4:1 to 8:1; a molar ratio of Al<1> to titanium tetrachloride from 0.9:1 to 1.5:1; a molar ratio of halide to Mg from 1.9:1 to 2.6:1; and a molar ratio of Al<2> to titanium from 2:1 to 4:1 comprising mixing in an inert hydrocarbon in a first reactor, two of the components and maintaining them at a temperature from 30 degree C to 70 degree C for a period of time from 2 to 15 minutes and adding the remaining catalyst components to the heat treated mixture, to the second reactor, or both. 2. The process according to claim 1, wherein the mole ratio of Al<1> to Ti is from 1:1 to 1.3 to 1. 3. The process according to claim 2, wherein the mole ratio of halide to Mg is from 1.9:1 to 2.5:1. 4. The process according to claim 3, wherein the mole ratio of Mg to  Al<1> is from 6:1 to 8:1. 5. The process according to claim 4, wherein the mole ratio of Mg to Ti is from 6:1 to 8:1. 6. The process according to claim 5, wherein the mole ratio of Al<1> to Ti is from 0.9:1 to 1.1 to 1. 7. The process according to claim 6, wherein the mole ratio of Al<2> to Ti is from 3:1 to 4:1. 8. The process according to claim 7, where in the mixture of the Al<1> compound and the magnesium compound and the halide are initially mixed and heat treated. 9. The process according to claim 8, wherein the time is from 2 to 10 minutes. 10. The process according to claim 8 wherein TiCl4 is added to the transfer line between the first and second reactor. 11. The process according to claim 10, wherein the Al<2> compound is added directly to the second reactor. 12. The process according to claim 8 wherein the Al<2> compound is added to the transfer line between the first and second reactor. 13. The process according to claim 8 wherein TiCl4 is added directly to the second reactor. 14. The catalyst, wherein R<1>, R<3>, R<4> and R<5> are independently selected from the group consisting of C1-4 alkyl radicals. 15. The catalyst according to claim 14, wherein R<1> is an ethyl radical. 16. The catalyst according to claim 15, wherein R<2> is a C2-6 alkyl radical. 17. The catalyst according to claim 16, wherein R<3> is a tertiary butyl radical. 18. The catalyst according to claim 17, wherein R<4>, and R<5> are ethyl radicals. 19. A process for the solution polymerization of a mixture comprising at least 40 weight % of ethylene and up to 60 weight % of one or more C3-12 alpha-olefins at a temperature from 105 degree C to 320 degree C and a pressure from 4 to 20 MPa in a chain of at least two continuous stirred reactors connected in series where the first reactor is used to react catalyst components and the subsequent reactors are for polymerization and the catalyst is according to claim 14.