EP0020818A1
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Process for preparing a polymerization catalyst and process for the production of ethylene polymers
Assignee: Union Carbide Corp
•
Filing: 1979-12-27
•
Granted: —
•
Expires: 1999-12-27
Abstract
Abstract A catalyst composition formed from selected organoaluminum compounds and a precursor composition of the formula wherein ED is a selected electron donor compound R is a C 1 to C 14 , aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, X is Cl, Br, 1, or mixtures thereof. Filler is an inert organic or inorganic compound, and, based on the total weight of such composition m is ≧ 0.5 to ≦ 56 in is 0 or 1 p is ≧ 6 to ≦ 116 q is ≧ 2 to ≦ 85 r has a value such that the percent filler is from about 10 to about 95 weight percent based on the total weight of the precursor composition. A process for preparing such precursor composition by spray drying it from a slurry or solution in said electron donor compound, using atomization. A process for using said catalyst to readily prepare ethylene polymers having a density of about ≧0.91 to ≦0.97, a melt flow ratio of ≧22 to ≦32 and a bulk density of about 18 to 32 lbs/ft 3 and controlled particle shape and size in a low pressure gas phase process at a productivity of ≧50,000 pounds of polymer per pound of Ti.
Inventors
- 👤 Anthony David Hamer
- 👤 Frederick John Karol
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-02 06:20
CPC Classifications
C; C08; C08F; C08F210/00; C08F210/16; C08F10/00; C08F10/02; Y; Y10; Y10S; Y10S526/00; Y10S526/904
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
387 words
A catalyst composition produced by A) forming a spherical precursor composition of the formula: wherein R is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, X is Cl, Br, I, or mixtures thereof, ED is an electron donor compound Filler is an inert filler compound, and, based on the total weight of said composition, m is ≥ 0.5 to ≤ 56, n is 0 or 1, p is >2 to <116, q is >2 to <85, and r has a value such that the percent filler is from about 10 to about 95 weight percent based on the total weight of said composition, by forming a slurry or solution of at least one magnesium compound and at least one titanium compound and at least one filler compound in at least one electron donor compound so as to thereby form a slurry or solution of said precursor composition in said electron donor compound and spray drying said slurry or solution by atomization to form spherical particles of said precursor composition which have a particle size of from about 10 to about 200 microns, said magnesium compound having the structure said titanium compound having the structure wherein a is 0, 1 or 2, b is 1 to 4 inclusive and a + b = 3 or 4, said electron donor compound being a liquid organic compound in which said magnesium compound and said titanium compound are soluble and which is selected from the group consisting.of alkyl esters of aliphatic and aromatic carboxylic acids, aliphatic ethers, cyclic ethers and aliphatic ketones, B) activating said precursor composition either by partially activating it with >0 to ≤10 mols of activator compound per mol of Ti in said precursor composition, or completely activating it with 10 to 500 mols of activator compound per mol of Ti in said precursor composition, said activator compound having the formula wherein X' is Cl or OR" ', R" and R" ' are the same or different, and are C 1 to C 14 saturated hydrocarbon radicals, d is 0 to 1.5, e is 1 or 0 and c + d + e = 3, said activating being conducted after the recovery of said particles of said precursor composition.
Claim 2
Dependent Claim
387 words
A catalyst composition produced by A) forming a spherical precursor composition of the formula: wherein R is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, X is Cl, Br, I, or mixtures thereof, ED is an electron donor compound Filler is an inert filler compound, and, based on the total weight of said composition, m is ≥ 0.5 to ≤ 56, n is 0 or 1, p is >2 to <116, q is >2 to <85, and r has a value such that the percent filler is from about 10 to about 95 weight percent based on the total weight of said composition, by forming a slurry or solution of at least one magnesium compound and at least one titanium compound and at least one filler compound in at least one electron donor compound so as to thereby form a slurry or solution of said precursor composition in said electron donor compound and spray drying said slurry or solution by atomization to form spherical particles of said precursor composition which have a particle size of from about 10 to about 200 microns, said magnesium compound having the structure said titanium compound having the structure wherein a is 0, 1 or 2, b is 1 to 4 inclusive and a + b = 3 or 4, said electron donor compound being a liquid organic compound in which said magnesium compound and said titanium compound are soluble and which is selected from the group consisting.of alkyl esters of aliphatic and aromatic carboxylic acids, aliphatic ethers, cyclic ethers and aliphatic ketones, B) activating said precursor composition either by partially activating it with >0 to ≤10 mols of activator compound per mol of Ti in said precursor composition, or completely activating it with 10 to 500 mols of activator compound per mol of Ti in said precursor composition, said activator compound having the formula wherein X' is Cl or OR" ', R" and R" ' are the same or different, and are C 1 to C 14 saturated hydrocarbon radicals, d is 0 to 1.5, e is 1 or 0 and c + d + e = 3, said activating being conducted after the recovery of said particles of said precursor composition.
Claim 3
Dependent Claim
15 words
A process as in claim 1 in which said magnesium compound comprises MgCl 2 .
Claim 4
Dependent Claim
19 words
A process as in claim 2 in which said electron donor compound comprises at least one ether, preferably tetrahydrofuran.
Claim 5
Dependent Claim
15 words
A process as in claim 3 in which said titanium compound comprises TiCl 4 .
Claim 6
Dependent Claim
115 words
A catalytic process for producing ethylene polymers selected from the group consisting of ethylene homopolymers and copolymers with a Ti containing catalyst at a productivity of >50,000 pounds of polymer per pound of Ti under a pressure of <1000 psi in the gas phase 1 said polymer being produced in granular spherical form having a particle size of from about 250 to about 2550 microns and having a density of ≥ 0.91 to ≤ 0.97 and melt flow ratio of ≥ 22 to ≤ 32 which comprises homopolymerizing or copolymerizing ethylene at a temperature of about 30 to 115° by contacting the monomer charge with spherical particles of the activated catalyst composition of claim 1.
Claim 7
Dependent Claim
14 words
A process as in claim 5 which is conducted in a fluid bed process.
Claim 8
Dependent Claim
24 words
A process as in claim 6 which is conducted under a mass gas flow rate of about 1.5 to 10 times G mf .
Claim 9
Dependent Claim
14 words
A process as in claim 7 which is conducted at a productivity of ≥100,000.
Claim 10
Dependent Claim
15 words
A process as in claim 7 which is conducted at a productivity of ≥ 200,000.
Claim 11
Dependent Claim
25 words
A process as in claim 5 in which ethylene is copolymerized with at least.one C 3 to C 8 alpha olefin, preferably butene-1 or propylene.
Claim 12
Dependent Claim
12 words
A granular spherical virgin polymer made by the process of claim 6.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
Maintenance schedule is calculated for granted US utility patents.