Patent RU-2736492-C2 (RU)
Title: Method of producing modified clay, metallocene polymerisation catalyst on a substrate, produced catalyst and use thereof
Inventor: JENSEN MICHAEL D
IPC: C08F4/06
Filed: 2016-05-09
Granted: 2020-11-17
Abstract: FIELD: chemistry. 
     SUBSTANCE: disclosed is a method of producing a catalyst support activator for metallocene catalyst compositions for olefin polymerisation, wherein said activator substrate comprises: intercalated smectite clay with cross-links containing aluminum and: (i) at least one rare-earth metal or a metal of a lanthanide group, selected from lanthanum and cerium; or (ii) at least one rare-earth metal or a metal of a lanthanide group selected from lanthanum and cerium, and gallium; wherein said clay contains at least one ion-exchange metal ion, which is selected from magnesium and zinc, comprising the following steps: (A) reacting an aqueous suspension containing smectite clay with an aqueous cross-linking agent containing aluminum and: (i) at least one rare-earth metal or a metal of a lanthanide group selected from lanthanum and cerium; or (ii) at least one rare-earth metal or a metal of a lanthanide group, selected from lanthanum and cerium, and gallium; to form a phase containing solid substances and an aqueous phase; (B) separating the phase containing solid substances from the aqueous phase formed at step (A); (C) after separation of phase containing solid substances at step (B), extraction of said phase containing solid substances, at least once with water, until, after separation from solid substances, separated water no longer contains or substantially contains: (i) residual anions originally present in the aqueous cross-linking agent; or (ii) unencumbered cross-linking agent or by-product thereof; or (iii) both (i) and (ii); (D) contacting separated solid substances obtained at step (C), at least once with aqueous composition Met m X n , containing at least one Met m X n , where Met m  is at least one metal ion, which is selected from magnesium and zinc, and X n  contains at least one anion group; and m and n are numbers which together satisfy valency requirements for the combination of Met m  and X n , to form a mixture containing a phase, containing solid substances, and aqueous phase; (E) separating the aqueous phase formed at step (D) to form a new phase containing solid substances; (F) after phase separation at phase (E), containing solid substances, extraction of this new phase containing solid substances, at least once with water, wherein extraction with water is repeated until after separation from solid substances the separated water will not contain or substantially will not contain: (i) residual anions, initially present in composition Met m X n ; or (ii) unspent composition Met m X n  or its by-product; or (iii) both (i) and (ii), where at stages (C) and (F) of water extraction absence or substantially absence is confirmed by conductivity value less than 20000 µS/cm, or negative test result with AgNO 3 , or by results of both tests; (G) drying the recovered phase containing solid substances obtained at step (F) to obtain dry solids and converting said solid substances into dry solid particles; and (H) calcining dry solid particles obtained at step (G) to form a dry cross-linked solid catalytic support activator in form of solid particles; wherein said catalytic activator substrate is characterized by interplanar distance (y) equal to or greater than 18.5 Angstroms and equal to or less than 100 Angstroms; wherein said catalytic activator support enables to activate metallocene catalyst compositions for olefin polymerisation in the absence of an alumoxane or borate activator. Invention also discloses a method of producing a metallocene catalyst composition for olefin polymerisation, which includes catalytic substrate-activator, which is described above, as well as disclosed is a catalytic metallocene olefin polymerisation composition obtained using said method. 
     EFFECT: technical result is improvement of catalytic substrates and methods of obtaining such substrates associated with cross-linked and additionally modified clays, which facilitate solving problems and meeting actual needs in the field of heterogeneous catalysis when producing polymers and, in particular, heterogeneous metallocene catalysts. 
     9 cl, 2 tbl, 2 ex