Catalyst composition for polymerizing alpha-olefins

Claim 2

A process for preparing a supported catalyst composition for use in alpha-olefin polymerization reactions, said process consisting essentially of the following steps in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be halogen, and n is 0, 1, or 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier; (ii) removing said liquid from step (i) to obtain a magnesium-containing carrier in the form of a dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula: R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula : Ti(OR").sub.m wherein R" is branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, said titanium (IV) alkoxide compound, said brominating and/or chlorinating agent being soluble in said liquid medium, and said magnesium-containing carrier being substantially insoluble in said liquid medium, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 3

A process of claim 1 wherein the number of moles of said titanium (IV) alkoxide compound present in said solution of step (iii) is in excess of the number of moles of the organomagnesium composition used in step (i).

Claim 4

A process of claim 2 wherein the solid, porous carrier, prior to contact thereof with liquid in step (i), is heated at a temperature of about 100° C. to about 1000° C.

Claim 5

A process of claim 3 wherein the solid, porous carrier is heated at a temperature of about 150° C. to about 850° C.

Claim 6

A process of claim 4 wherein the carrier is heated at a temperature of about 800° C.

Claim 7

A process of claim 5 wherein the heating is continued until the carrier contains about 0.5 to about 5 mmoles of the OH groups per gram of carrier.

Claim 8

A process of claim 6 wherein the heating is continued until the carrier contains about 0.3 to about 0.7 mmoles of the OH groups per gram of carrier.

Claim 9

A process of claim 7 wherein the carrier is silica having a surface hydroxyl group concentration of about 0.5 mmoles/gr, a surface area of 300 m 2 /gram and a pore volume of 1.65 m 3 /gram.

Claim 10

A process of claim 8 wherein R is a C 1 -C 4 alkane group and R' is a halogen.

Claim 11

A process of claim 9 wherein R' is bromine or chlorine.

Claim 12

A process of claim 10 wherein the organomagnesium composition is ethylmagnesium chloride.

Claim 13

A process of claim 11 wherein the liquid containing ethylmagnesium chloride is tetrahydrofuran.

Claim 14

A process of claim 12 wherein said liquid is removed in step (ii) by evaporation.

Claim 15

A process of claim 13 wherein the molar ratio of the organomagnesium composition to the number of moles of the OH groups on the carrier is about 1.1 to about 3.5.

Claim 16

A process of claim 14 wherein R" is a branched or unbranched alkyl radical of 1 to 6 carbon atoms.

Claim 17

A process of claim 15 wherein R" is isopropoxide.

Claim 18

A process of claim 16 wherein R"' is C 1 -C 4 branched or unbranched alkyl group.

Claim 19

A process of claim 17 wherein the brominating or chlorinating agent is ethylaluminum dichloride.

Claim 20

A process of claim 18 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 2:1 to about 15:1.

Claim 21

A process of claim 19 wherein the molar ratio of ethylaluminum dichloride to titanium isoproxide ranges from about 2:1 to about 8:1.

Claim 22

A supported catalyst composition for use in alpha-olefin polymerization reactions prepared by the process consisting essentially of the following steps conducted in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be halogen, and n is 0, 1 or 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier; (ii) removing said liquid from step (i) to obtain a magnesium-containing carrier in the form of a dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula : R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula: Ti(OR").sub.m wherein R" is a branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, said titanium (IV) alkoxide compound and said brominating and/or chlorinating agent being soluble in said liquid medium, and said magnesium-containing carrier being substantially insoluble in said liquid medium, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 23

A supported catalyst composition for use in alpha-olefin polymerization reactions prepared by the process consisting essentially of the following steps conducted in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be halogen, and n is 0, 1 or 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier; (ii) removing said liquid from step (i) to obtain a magnesium-containing carrier in the form of a dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula : R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula: Ti(OR").sub.m wherein R" is a branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, said titanium (IV) alkoxide compound and said brominating and/or chlorinating agent being soluble in said liquid medium, and said magnesium-containing carrier being substantially insoluble in said liquid medium, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 24

A catalyst composition of claim 21 wherein the number of moles of said titanium (IV) alkoxide compound present in said solution of step (iii) is in excess of the number of moles of the organomagnesium composition used in step (i).

Claim 25

A catalyst composition of claim 22 wherein the solid, porous carrier, prior to contact thereof with the liquid in step (i), is heated at a temperature of about 100° C. to about 1000° C.

Claim 26

A catalyst composition of claim 23 wherein the solid, porous carrier is heated at a temperature of about 150° C. to about 850° C.

Claim 27

A catalyst composition of claim 24 wherein the carrier is heated at a temperature of about 800° C.

Claim 28

A catalyst composition of claim 25 wherein the heating is continued until the carrier contains about 0.5 to about 5 mmoles of the OH groups per gram of carrier.

Claim 29

A catalyst composition of claim 26 wherein the heating is continued until the carrier contains about 0.3 to about 0.7 moles of the OH groups per gram of carrier.

Claim 30

A catalyst composition of claim 27 wherein the carrier is silica having a surface hydroxyl group concentration of about 0.5 mmoles/gr, a surface area of 300 m 2 /gram and a pore volume of 1.65 m 3 /gram.

Claim 31

A catalyst composition of claim 28 wherein R is a C 1 -C 4 alkane group and R' is halogen.

Claim 32

A catalyst composition of claim 29 wherein R' is bromine or chlorine.

Claim 33

A catalyst composition of claim 30 wherein the organomagnesium composition is ethylmagnesium chloride.

Claim 34

A catalyst composition of claim 31 wherein the liquid containing ethylmagnesium chloride is tetrahydrofuran.

Claim 35

A catalyst composition of claim 32 wherein said liquid is removed in step (ii) by evaporation.

Claim 36

A catalyst composition of claim 33 wherein the molar ratio of the organomagnesium composition to the number of moles of the OH groups on the carrier is about 1.1 to about 3.5.

Claim 37

A catalyst composition of claim 34 wherein R" is a branched or unbranched alkyl radical of 1 to 6 carbon atoms.

Claim 38

A catalyst composition of claim 35 wherein R" is isopropoxide.

Claim 39

A catalyst composition of claim 36 wherein R"' is C 1 -C 4 branched or unbranched alkyl group.

Claim 40

A catalyst composition of claim 37 wherein the brominating and/or chlorinating agent is ethylaluminum dichloride.

Claim 41

A process of claim 38 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 2:1 to about 15:1.

Claim 42

A catalyst composition of claim 39 wherein the molar ratio of ethylaluminum dichloride to titanium isoproxide ranges from about 2:1 to about 8:1.

Claim 43

A process for preparing a polymer of at least one C 2 -C 10 alphaolefin, the polymer having MFR values of about 25 to about 65, polymer containing at least about 80 percent by weight of ethylene units, the process comprising conducting the polymerization in the presence of a catalyst prepared by a process consisting essentially of the following steps conducted in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be a halogen, and n is 0, 1 or 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier; (ii) removing said liquid from step (i) to obtain a magnesium-containing carrier in the form of a dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula: R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula: Ti(OR").sub.m wherein R" is a branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, said titanium (IV) alkoxide compound and said brominating and/or chlorinating agent being soluble in said liquid medium, and said supported magnesium-containing carrier being substantially insoluble in said liquid medium, the molar ratio of said brominating and/or chlorinating agent to said titanium (IV) alkoxide compound being sufficient to produce said alpha-olefin polymers having MFR values of about 25 to about 65, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 44

A process for preparing a polymer of at least one C 2 -C 10 alphaolefin, the polymer having MFR values of about 25 to about 65, polymer containing at least about 80 percent by weight of ethylene units, the process comprising conducting the polymerization in the presence of a catalyst prepared by a process consisting essentially of the following steps conducted in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be a halogen, and n is 0, 1 or 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier; (ii) removing said liquid from step (i) to obtain a magnesium-containing carrier in the form of a dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula: R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula: Ti(OR").sub.m wherein R" is a branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, said titanium (IV) alkoxide compound and said brominating and/or chlorinating agent being soluble in said liquid medium, and said supported magnesium-containing carrier being substantially insoluble in said liquid medium, the molar ratio of said brominating and/or chlorinating agent to said titanium (IV) alkoxide compound being sufficient to produce said alpha-olefin polymers having MFR values of about 25 to about 65, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 45

A process of claim 41 wherein the number of moles of said titanium (IV) alkoxide compound present in said solution of (iii) is in excess of the number of moles of the organomagnesium composition used in step (i).

Claim 46

A process of claim 42 wherein the polymer is selected from the group consisting of ethylene homopolymer, ethylene/1-butene copolymer, ethylene/1-hexene copolymer, ethylene/4-methyl-1-pentene copolymer, ethylene/1-butene/1-hexene terpolymer and ethylene/propylene/1-butene terpolymer.

Claim 47

A process of claim 43 wherein the polymer is an ethylene/1-hexene copolymer having a density of about 0.910 to about 0.970 gms/cc.

Claim 48

A process of claim 44 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 1:1 to about 30:1.

Claim 49

A process of claim 45 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 2:1 to about 15:1.

Claim 50

A process of claim 46 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 2:1 to about 8:1.

Claim 51

A process of claim 47 wherein the number of moles of said titanium (IV) alkoxide compound present in said solution of step (iii) is in excess of the number of moles of the organomagnesium composition used in step (i).

Claim 52

A process of claim 48 wherein the solid, porous carrier, prior to contact thereof with the liquid in step (i), is heated at a temperature of about 100° C. to about 1000° C.

Claim 53

A process of claim 49 wherein the solid, porous carrier is heated at a temperature of about 150° C. to about 850°.

Claim 54

A process of claim 50 wherein the carrier is heated at a temperature of about 800° C.

Claim 55

A process of claim 51 wherein the heating is continued until the carrier contains about 0.5 to about 5 mmoles of the OH groups per gram of carrier.

Claim 56

A process of claim 52 wherein the heating is continued until the carrier contains about 0.3 to about 0.7 mmoles of the OH groups per gram of carrier.

Claim 57

A process of claim 53 wherein the carrier is silica having a surface hydroxyl group concentration of about 0.5 mmoles/gr, a surface area of 300 m 2 /gram and a pore volume of 1.65 m 3 /gram.

Claim 58

A process of claim 54 wherein R is a C 1 -C 4 alkane group and R' is a halogen.

Claim 59

A process of claim 55 wherein R' is bromine or chlorine.

Claim 60

A process of claim 56 wherein the organomagnesium composition is ethylmagnesium chloride.

Claim 61

A process of claim 57 wherein the liquid containing ethylmagnesium chloride is tetrahydrofuran.

Claim 62

A process of claim 58 wherein said liquid is removed in step (ii) by evaporation.

Claim 63

A process of claim 59 wherein the molar ratio of the organomagnesium composition to the number of moles of the OH groups on the carrier is about 1.1 to about 3.5.

Claim 64

A process of claim 60 wherein R" is a branched or unbranched alkyl radical of 1 to 6 carbon atoms.

Claim 65

A process of claim 61 wherein R" is isopropoxide.

Claim 66

A process of claim 62 wherein R"' is a C 1 -C 4 branched or unbranched alkyl group.

Claim 67

A process of claim 63 wherein the brominating or chlorinating agent is ethylaluminum dichloride.

Claim 68

A supported catalyst composition for use in alpha-olefin polymerization reactions prepared by the process consisting essentially of the following steps conducted in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be a halogen, and n is 0, 1 or 2; (ii) removing said liquid from step (i) to obtain a magnesium-containing, dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula: R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula: Ti(OR").sub.m wherein R" is a branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, the number of moles of said titanium (IV) alkoxide compound being in excess of the number of moles of said organomagnesium composition in step (i), said titanium (IV) alkoxide compound and said brominating and/or chlorinating agent being soluble in said liquid medium, and said magnesium-containing carrier being substantially insoluble in said liquid medium, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 69

A supported catalyst composition for use in alpha-olefin polymerization reactions prepared by the process consisting essentially of the following steps conducted in the recited order: (i) contacting a solid, porous carrier having reactive OH groups with a liquid, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R and R' are the same or different and they are C 1 -C 12 hydrocarbyl groups, provided that R' may also be a halogen, and n is 0, 1 or 2; (ii) removing said liquid from step (i) to obtain a magnesium-containing, dry, free-flowing powder; and (iii) contacting said powder of step (ii) with a solution comprising a liquid medium, an aluminum-containing brominating and/or chlorinating agent having the formula: R"'.sub.p AlX.sub.(3-p) wherein R"' is a C 1 -C 12 branched or unbranched alkyl group, X is bromine or chlorine, and p is 1 or 2, and at least one titanium (IV) alkoxide compound having the formula: Ti(OR").sub.m wherein R" is a branched or unbranched alkyl radical of 1 to 20 carbon atoms and m is 4, the number of moles of said titanium (IV) alkoxide compound being in excess of the number of moles of said organomagnesium composition in step (i), said titanium (IV) alkoxide compound and said brominating and/or chlorinating agent being soluble in said liquid medium, and said magnesium-containing carrier being substantially insoluble in said liquid medium, whereby a compound of titanium which is insoluble in said liquid medium becomes incorporated onto said carrier.

Claim 70

A catalyst composition of claim 65 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 1:1 to about 30:1.

Claim 71

A catalyst composition of claim 66 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 2:1 to about 15:1.

Claim 72

A catalyst composition of claim 67 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium alkoxide compound is about 2:1 to about 8:1.

Claim 73

A catalyst composition of claim 68 wherein the number of moles of said titanium (IV) alkoxide compound present in said solution of step (iii) is in excess of the number of moles of the organomagnesium composition used in step (i).

Claim 74

A catalyst composition of claim 69 wherein the molar ratio of tetravalent of the titanium (IV) alkoxide compound to the organomagnesium composition is about 3 to about 6.

Claim 75

A catalyst composition of claim 70 wherein the solid, porous carrier, prior to contact thereof with the liquid in step (i), is heated at a temperature of about 100° C. to about 1000° C.

Claim 76

A catalyst composition of claim 71 wherein the solid, porous carrier is heated at a temperature of about 150° C. to about 850°.

Claim 77

A catalyst composition of claim 72 wherein the carrier is heated at a temperature of about 800° C.

Claim 78

A catalyst composition of claim 73 wherein the heating is continued until the carrier contains about 0.5 to about 5 mmoles of the OH group per gram of carrier.

Claim 79

A catalyst composition of claim 74 wherein the heating is continued until the carrier contains about 0.3 to about 0.7 mmoles of the OH groups per gram of carrier.

Claim 80

A catalyst composition of claim 75 wherein the carrier is silica having a surface hydroxyl group concentration of about 0.5 mmoles/gr, a surface area of 300 m 2 /gram and a pore volume of 1.65 m 3 /gram.

Claim 81

A catalyst composition of claim 76 wherein R is a C 1 -C 4 alkane group and R' is a halogen.

Claim 82

A catalyst composition of claim 77 wherein R' is bromine or chlorine.

Claim 83

A catalyst composition of claim 78 wherein the organomagnesium composition is ethylmagnesium chloride.

Claim 84

A catalyst composition of claim 79 wherein the liquid containing ethylmagnesium chloride is tetrahydrofuran.

Claim 85

A catalyst composition of claim 80 wherein said liquid is removed in step (ii) by evaporation.

Claim 86

A catalyst composition of claim 81 wherein the molar ratio of the organomagnesium composition to the number of moles of the OH groups on the carrier is about 1.1 to about 3.5.

Claim 87

A catalyst composition of claim 82 wherein R" is a branched or unbranched alkyl radical of 1 to 6 carbon atoms.

Claim 88

A catalyst composition of claim 83 wherein R" is isopropoxide.

Claim 89

A catalyst composition of claim 84 wherein R"' is a C 1 -C 4 branched or unbranched alkyl group.

Claim 90

A catalyst composition of claim 85 wherein the brominating or chlorinating agent is ethylaluminum dichloride.

Claim 91

A catalyst composition of claim 86 wherein the molar ratio of the brominating and/or chlorinating agent to the titanium isopropoxide compound is about 2:1 to about 15:1.

Claim 92

A catalyst composition of claim 87 wherein the molar ratio of ethylaluminum dichloride to titanium isoproxide ranges from about 2:1 to about 8:1.