Patent Description:
Gas-phase polymerization is a technique for the preparation of polyethylene which can be carried out in a fluidized or stirred-bed reactor in the presence of a catalyst, ethylene, fluidization gas and molecular weight regulator such as hydrogen.

Catalyst performance for gas-phase ethylene polymerization activity may depend on the polymerization conditions, such as temperature and pressure. However, once the polymerization conditions are fixed the activity depends strictly on the catalyst system. When the activity of the catalyst system is not satisfactory the amount of catalyst fed to the reactor and/or the residence time may be increased. However, these changes increase the plant operability costs because the increase of catalyst fed means an increase of the cost per unity of polymer produced, while the increase of the residence time means a lower productivity of the plant.

Titanium (Ti) based Ziegler-Natta catalysts may be used for the gas-phase polymerization of ethylene in combination with aluminum alkyl compounds. For instance, <CIT> discloses a gas-phase polymerization process carried out in the presence of a catalyst component comprising a Ti compound and tetrahydrofuran supported on a magnesium (Mg) based compound. Before being introduced in the polymerization reactor, the catalyst component is pre-activated by contacting it sequentially with an aluminum trialkyl compound and then with a chlorinated aluminum alkyl compound. The ratio between the total molar amount of the aluminum alkyls used with respect to the tetrahydrofuran in the catalyst may be about <NUM>, while the ratio between the chlorinated aluminum alkyl compound and the trialkyl aluminum compound is higher than <NUM>. These specific amounts and the relative ratios of the various components of the preactivation stage are effective mainly for modulating the melt flow rate (MFR).

The applicant has surprisingly found that catalytic activity may be increased by changing the relative ratio among the reactants.

An object of the present disclosure includes a process for pre-activating a catalyst for the polymerization of olefins comprising:.

In some embodiments, the aluminum compound (ii) of the formula AlR<NUM> is selected from compounds in which R is a C<NUM>-C<NUM> alkyl group, including a linear alkyl group. For instance, compounds for use in the present technology are tri-n-hexyl aluminum and tri-n-octyl aluminum.

In certain embodiments, the aluminum compound (iii) of the formula AlClnR<NUM>-n is selected from compounds in which n ranges from <NUM> to <NUM> and R is a C<NUM>-C<NUM> alkyl group. Compounds that may be used in accordance with the present disclosure are ethylaluminum dichloride, diethylaluminum chloride and ethylaluminum sesquichloride.

Preferably, the molar ratio of compounds (iii)/(ii) ranges from <NUM> to <NUM>, more preferably from <NUM> to <NUM>.

Preferably, the molar ratio between the sum of the aluminum compounds (ii) and (iii) and the ether present in the solid catalyst component (i) ranges from <NUM> to <NUM>, more preferably from <NUM>-<NUM>.

In a preferred embodiment, the molar ratio between the sum of the aluminum compounds (ii) and (iii) and the ether present in the solid catalyst component (i) ranges from <NUM> to <NUM>, and the molar ratio of compounds (iii)/(ii) ranges from <NUM> to <NUM>.

In another preferred embodiment, the molar ratio between the sum of aluminum compounds (ii) and (iii) and the ether present in the solid catalyst component (i) ranges from <NUM> to <NUM>, and the molar ratio of compounds (iii)/(ii) ranges from <NUM> to <NUM>.

The use of tri-n-hexyl aluminum as compound (ii) and diethyl aluminum chloride as compound (iii) is preferred.

Preferably, the contacting of the components in step (a) is carried out for a period of time ranging from <NUM> to <NUM> minutes, more preferably from <NUM> to <NUM> minutes.

Preferably, the contact in step (a) is carried out in a liquid diluent at a temperature ranging from <NUM> to <NUM>, more preferably from <NUM> to <NUM>.

In a preferred aspect, the contacting of the components in step (b) is carried out for a period of time shorter than the contact time in (a), such as from <NUM>-<NUM> minutes and preferably from <NUM>-<NUM> minutes. It is also preferred carrying out the contact step (b) at a temperature ranging from <NUM>-<NUM>, preferably such as from <NUM>-<NUM>. Step (b) may take place in an inert diluent.

The titanium compounds in the solid catalyst component (i) may have the general formula Ti(ORI)mXy-m, where m is <NUM>-<NUM> inclusive, y is the valence of titanium, RI is an alkyl, cycloalkyl or aryl radical having <NUM>-<NUM> carbon atoms, and X is a halogen. For instance, RI can be an ethyl, isopropyl, n-butyl, isobutyl, <NUM>-ethylhexyl, n-octyl and phenyl(benzyl) group, while X may be chlorine.

In certain embodiments, if y is <NUM>, m is from <NUM>-<NUM>, and if y is <NUM>, m is from <NUM> to <NUM>. In some embodiments, TiCl<NUM> is used as the titanium compound.

Preferably, the Mg/Ti molar ratio ranges from <NUM> to <NUM>, more preferably from <NUM> to <NUM>.

The solid catalyst component (i) also comprises an ether as internal donor. The ether (E) is present in amount such as to give (E)/Ti molar ratios from <NUM> to <NUM>, preferably from <NUM> to <NUM> and more preferably from <NUM> to <NUM>.

Preferably, ethers such as cyclic alkyl ethers having from <NUM>-<NUM> carbon atoms may be used with tetrahydrofuran being particularly preferred.

In some embodiments the solid catalyst component (i) may comprise a porosity PF (deriving from pores with radius up to <NUM>µ) as determined using the mercury method of <NUM>-<NUM><NUM>/g, including from <NUM>-<NUM><NUM>/g.

In certain embodiments, the surface area measured by the BET method may be lower than <NUM>, such as from <NUM>-<NUM><NUM>/g. The porosity as measured by the Brunauer-Emmett-Teller (BET) method may range from <NUM>-<NUM><NUM>/g, including from <NUM>-<NUM><NUM>/g.

The particles of the solid component of the catalyst system may have a spherical morphology and an average diameter ranging from <NUM>-<NUM>, including from <NUM>-<NUM>. As used herein, "particles having spherical morphology" and related phrases are used to describe particles comprising a ratio between the greater axis and the smaller axis equal to or lower than <NUM>, such as lower than <NUM>.

In some embodiments, a method for the preparation of spherical components described herein comprises a step (a) in which a compound MgCl<NUM>. mRIIOH, where <NUM> ≤ m ≤ <NUM> and RII is an alkyl, cycloalkyl or an aryl radical having <NUM>-<NUM> carbon atoms, is reacted with a titanium compound of the general formula Ti(ORI)nX<NUM>-n, in which n, y, X and RI have the same meaning as defined above.

Preferably, MgCl<NUM>. mRIIOH comprises a precursor of a Mg dihalide compound for use in the present technology. These compounds can be obtained by mixing alcohol and magnesium chloride in the presence of an inert hydrocarbon immiscible with a spherical adduct under stirring conditions at the melting temperature of the adduct (<NUM>-<NUM>). The emulsion is quickly quenched, causing the solidification of the adduct in form of spherical particles. Representative methods for the preparation of such spherical adducts are reported, for example, in <CIT> and <CIT>, and WIPO <CIT>. Another method involves spray cooling as described in <CIT> and <CIT>. Adducts having a functional alcohol content can be obtained by directly using the selected amount of alcohol directly during the adduct preparation. However, if adducts with increased porosity are required one may first prepare the adducts with more than <NUM> moles of alcohol per mole of MgCl<NUM>, which can then be subjected to a thermal and/or chemical dealcoholation process. The thermal dealcoholation process may be carried out under nitrogen flow at temperatures between <NUM>-<NUM> until the alcohol content is reduced to the value ranging from <NUM>-<NUM>. A process of this type is described in <CIT>.

The dealcoholated adducts may also be characterized by a porosity (as measured by the mercury method ), due to pores with radius up to <NUM>, ranging from <NUM> to <NUM><NUM>/g, preferably from <NUM>-<NUM><NUM>/g.

In some embodiments, in the reaction of step (a) the molar ratio Ti/Mg is stoichiometric or higher; for instance this ratio may be higher than <NUM>, or a large excess of titanium compound is used. In certain embodiments, titanium compounds for use in the present technology are titanium tetrahalides such as TiCl<NUM>. The reaction with the Ti compound can be carried out by suspending the adduct in cold TiCl<NUM> (such as at a temperature of about <NUM>); the mixture may then be heated up to <NUM>-<NUM> and kept at this temperature for <NUM>-<NUM> hours, such as <NUM>-<NUM> hours. Excess titanium compound that may be present can be separated at high temperatures by filtration or sedimentation and siphoning. The step (a) can be repeated twice or more.

In a subsequent step (b), the intermediate solid may be brought into contact with the ether compound under conditions able to affix it on the solid produced in step (a).

In certain embodiments, the reaction is carried out under conditions such that the ether is added to the reaction mixture alone or in a mixture with other compounds in which it represents the main component in terms of molar concentration. Although not required, the contact may optionally be carried out in a liquid medium such as a liquid hydrocarbon. The temperature at which the contact takes place can vary depending on the nature of the reagents and may range from -<NUM> to <NUM>, including from <NUM>- <NUM>. Temperatures that may cause the decomposition or degradation of any specific reagents should be avoided. Also, the time of the treatment can vary depending on other conditions such as nature of the reagents, temperature, concentration, etc. As a general indication, the contact step can last from <NUM> minutes to <NUM> hours, such as from <NUM>-<NUM> hours. In order to further increase the final donor content, this step can optionally be repeated one or more times. At the end of this step, the solid is recovered by separation of the suspension via the conventional methods (such as settling and removing of the liquid, filtration, centrifugation, etc.) and can be subject to washings with solvents. Although the washings may be carried out with inert hydrocarbon liquids, it is also possible to use more polar solvents (having, for example, a higher dielectric constant) such as halogenated or oxygenated hydrocarbons.

In a preferred embodiment, a further the step (c) is carried out where the solid product recovered from step (b) is subject to a thermal treatment at temperatures ranging from <NUM> to <NUM>, preferably from <NUM> to <NUM>, and more preferably from <NUM>-<NUM>.

The thermal treatment can be carried out in several ways. According to one of these methods, the solid coming from step (b) may be suspended in an inert diluent like a hydrocarbon and then subjected to the heating while maintaining the system under stirring.

According to an alternative technique, the solid can be heated in a dry state by inserting it in a device having jacketed heated walls. Stirring can be provided by means of mechanical stirrers placed within the device by using rotating devices such as magnetic stirrers.

According to a still further embodiment, the solid produced in step (b) can be heated by subjecting it to a flow of hot inert gas such as nitrogen, while optionally maintaining the solid under fluidization conditions.

In some embodiments, the heating time is not fixed but may vary depending on conditions such as the maximum temperature reached. The heating time may range, in certain embodiments, from <NUM>-<NUM> hours, including from <NUM>-<NUM> hours. Those skilled in the art understand that higher temperatures could allow the heating time to be shorter while lower temperatures may cause longer reaction times.

In the process as described herein, each of steps (b)-(c) can be carried out immediately after the previous step, without the need for isolating the solid product coming from the previous step. However, if desired the solid product coming from one step can be isolated and washed before being subjected to the subsequent step.

After the activation step with compounds (ii) and (iii), the pre-activated catalyst (A) can be contacted with a catalyst component (B) in order to complete the activation and form the final catalyst system used to polymerize olefins.

The catalyst component (B) (also called the cocatalyst) is selected from Al-alkyl compounds that are optionally halogenated. In some embodiments, is the cocatalyst is selected from Al-trialkyl compounds, for example Al-trimethyl, Al-triethyl , Al-tri-n-butyl , and Al-triisobutyl compounds. In certain embodiments, the Al/Ti ratio is higher than <NUM>, such as from <NUM>-<NUM>.

The contact between the preactivated catalyst and the catalyst component (B) can take place according to several different embodiments. For example, the two components can be fed separately into the polymerization reactor under polymerization conditions. In another embodiment, the components can be mixed upfront and then fed together into the polymerization reactor.

According to one embodiment, ethylene, optionally in a mixture with C<NUM>-C<NUM> alpha-olefins, is polymerized in gas phase in the further presence of the catalyst of the present disclosure.

The gas-phase polymerization process of the present disclosure can be carried out at a temperature ranging from <NUM>-<NUM>, preferably from <NUM> to <NUM>, in any type of gas-phase reactor. The total pressure of the gas-phase reactor may range from <NUM>-<NUM> bar, including from <NUM>-<NUM> bar. The fluidizing inert gas may comprise any inert gas described herein, including nitrogen and propane. Hydrogen may be used as a molecular weight regulator.

The gas-phase reactor can be a fluidized bed reactor such as those disclosed in <CIT> and <CIT>. In certain embodiments, two reactors in series can be employed to carry out the polymerization.

According to one embodiment, a gas-phase process for the polymerization of olefins comprises the following steps in any mutual order:.

In the second polymerization zone (the downcomer), the polymer particles flow under the action of gravity in a densified form such that high density values are reached (as defined by mass of polymer per volume of reactor), which approaches the bulk density of the polymer. In other words, the polymer flows vertically down through the downcomer in a plug flow (packed flow mode), so that small quantities of gas are entrained between the polymer particles.

In addition to the ethylene homo- and copolymers mentioned above, the catalysts of the present disclosure can also be used for preparing very-low-density and ultra-low-density polyethylenes (VLDPE and ULDPE, respectively) having densities of <NUM>-<NUM>/cm<NUM> and consisting of ethylene copolymers with one or more alpha-olefins comprising <NUM>-<NUM> carbon atoms, a molar content of units derived from ethylene of higher than <NUM>%, and elastomeric copolymers of ethylene and propylene and elastomeric terpolymers of ethylene and propylene with smaller proportions of a diene having a content by weight of units derived from ethylene of about <NUM>-<NUM>%.

The following examples are given in order to further describe the present disclosure in a non-limiting manner.

The properties are determined according to the following methods:.

The polymerization process was carried out in a plant working continuously and equipped with a pre-activation section in which the catalyst components are mixed to form the catalytic system, and one fluidized bed reactor (polymerization reactor) kept under fluidization conditions with propane for receiving the catalyst mixture coming from the stirred vessel.

In the preactivation vessel, a solid catalyst component prepared according to Example <NUM> of WIPO Pat. No. <CIT> is first contacted in liquid propane with tri-n-hexyl aluminum (THA). Subsequently, diethyl aluminum chloride (DEAC) is added to the previously formed mixture. The specific amounts of reactants, stirring times and temperatures are reported in Table <NUM>.

The resulting catalytic system was fed, via liquid propane, from the pre-activation section to the gas-phase fluidized bed reactor together with the monomer feed. Also, TEAL cocatalyst was fed to the reactor via a separate line. The operating conditions are reported in Table <NUM>. The polymer discharged from the final reactor was first transferred to the steaming section and then dried at <NUM> under a nitrogen flow and weighed. The polymer properties are reported in Table <NUM>.

Claim 1:
A process for activating a catalyst for the polymerization of olefins comprising :
(a) contacting a solid catalyst component (i) comprising a titanium compound, a magnesium compound and an ether compound with (ii) an aluminum compound of the general formula AlR<NUM>, in which R is a C<NUM>-C<NUM> linear or branched alkyl compound;
(b) contacting the product from step (a) with an aluminum compound (iii) of the general formula AlClnR<NUM>-n, in which n ranges from <NUM> to less than <NUM> and R is a C<NUM>-C<NUM> linear or branched alkyl compound, and comprising a molar ratio between the aluminum compound (iii) and the aluminum compound (ii) of <NUM> or less, and a molar ratio between the sum of aluminum compound (ii) and (iii) and the ether present in the solid catalyst component (i) of equal to, or lower than, <NUM>.