CA1078808A - Catalysts and catalyst components for polymerizing olefins - Google Patents
Catalysts and catalyst components for polymerizing olefinsInfo
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- CA1078808A CA1078808A CA259,430A CA259430A CA1078808A CA 1078808 A CA1078808 A CA 1078808A CA 259430 A CA259430 A CA 259430A CA 1078808 A CA1078808 A CA 1078808A
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
Abstract
ABSTRACT
Solid catalyst components are described which contain Ti, Mg and halogens. These components are reacted with Al metallorganic compounds to provide catalysts which are used for polymerizing .alpha.-olefins. Such a catalyst component is prepared by reacting a Ti compound with the solid halo-genation product obtained by reaction of a halogenating agent, different from the halogenated Ti compounds, with a Mg compound selected from the group consisting of:
(a) organic oxygenated magnesium compounds containing at least a Mg-O-R linkage wherein R is an alkyl- or cycloalkyl-radical containing up to 20 carbon atoms, (b) metallorganic Mg compounds containing at least a Mg-R linkage wherein R is an alkyl-, cycloalkyl-, aryl-radical containing up to 20 carbon atoms;
(c) Mg compounds containing at least a
Solid catalyst components are described which contain Ti, Mg and halogens. These components are reacted with Al metallorganic compounds to provide catalysts which are used for polymerizing .alpha.-olefins. Such a catalyst component is prepared by reacting a Ti compound with the solid halo-genation product obtained by reaction of a halogenating agent, different from the halogenated Ti compounds, with a Mg compound selected from the group consisting of:
(a) organic oxygenated magnesium compounds containing at least a Mg-O-R linkage wherein R is an alkyl- or cycloalkyl-radical containing up to 20 carbon atoms, (b) metallorganic Mg compounds containing at least a Mg-R linkage wherein R is an alkyl-, cycloalkyl-, aryl-radical containing up to 20 carbon atoms;
(c) Mg compounds containing at least a
Description
i , r, ~ ~ CASE FE. 2176 I ~ ,~.o~788V~
.
.I CA~ALYSrrS ~ND CAT~LYST ~O~II'ON~NTS ~OI~ POLYMEI~IZING
OLE~INSI~
in the namc of Montedison S.p.A.~ ~lan, (Italy), .
*~ *~
This invention relates to catalyst components for polymer_ izin~ ole~ins comprising compounds containing Ti, Mg and halogens, to the catalysts obtained by reacting such com-ponents with Al metallorganic compounds, and to processes for polymerizin~ olefins in which such catalysts are emplo~
ed.
From Italian patent No. ~32,438 in the name of the Applicant, catalysts are known suited to the polymerization of alpha-ole fins and propylene in particular, which are provided with a high activity and a good stereo~pecificity, consisting of the pro-duct of the reaction between an aluminium alkyl, partially com plexed with a Lewis base, and a solid catalyst component com-p~ising compounds of at least Ti, k~r and optionally complexed with a Lewis base.
. ,-Such catalyst components are generally prepared by grinding a mixture of a Ti halogenated compound with a Mg halide and a Lewis base. The Ti compound may be employed in the form of a complex previously prepared with the Lewis base.
',' ! 1 . . , ~ . . .
.
In order to ob~ain good resul~s from the catalysts obtained from these components, it is necessary that the Mg halide is present in a particularly activated form.
If one tries to employ, in the above-mentioned catalyst components, a Mg halide in the activated form, obtained, by reaction of a Mg alcoholate with a Ti halogenated compound (for example TiCl4), catalysts are obtained, by reaction with aluminium alkyls, which exhibit not quite ;~
satisfactory activity and s~ereospecificity, Analogously, if the magnesium halide in activated form is prepared by reacting a compound of formula RMgX (in which R is a hydrocarbon radical and X may be like R or a halogen) with a Ti halogenated compound, the-solid com~onents thus obtained provide, by reaction with aluminium alkyls, catalysts exhibiting not very high acti~ity and stereoregularity.
It has now surprisingly been found that it is possible to polymerize alpha olefins like propylene, butene-l, with catalysts exhibiting good characteristics of activity .
and stereoregularity, even starting from a catalyst component prepared from organic magnesium compounds including the RMgX
compounds and the magnesium alcoholates.
In the case of the polymerization of ethylene, it has been found that sald catalysts provide polymers whose particle size is comprised in a very narrow range.
The catalysts according to the present invention comprise the product of the reaction of:
A~ an addition and/or substitutlon product of an : ' t~ electron-donor compound ~such as a~Lewis base) ~ -2-~- ~m:PG ' ' ~
~ 10~7880~3 wi.th me~allorganic aluminium compound free of halogen atoms bound to the Al atoms, in which product the molar ratio between the electron-donor groups of the electron-donor compound which are reacted with the metallorganic Al compound and the total moles of the Al compound is comprised between 0~01 and 1, with B) a solid component comprising compounds containing ; 10 Ti, Mg and halogens, in which the halogen/Mg atomic ratio is not less than 1, said solid component being prepared by reacting a Ti compound .
with the solid halogenation product obtained by reaction of a halogenating agent, different from the halogenated Ti compound, with a Mg compound - selected from the group consisting of:
b.l) organic oxygenated magnesium compounds oontaining.at least a Mg-0-R linkage whereLn R is an alkyl- or cycloalkyl-radical containing up to ~, ~
20:~: 20 carbon atoms;
~ b.2)~ metallorganic Mg compounds containing at - : . .. .
~ least a Mg-R linkage wherein R is an alkyl-, : ::
: - ~ cycloalkyl- or aryl- radical containing up to 20 carbon atoms;
b.3) Mg compound~s containing at least a Mg- ~ R' : linkage, wherein~:R and R' may be H or alkyl- or aryl-radicals, ~ sald solid component being further characterized in that it :~ : comprises an electron-donor compound ~such as a Lewis base) :
. _3 ~, .
.
0~78~
in c~uanl:it~ nol: more than 1 mole per g-atom oE Mg.
The texm " addition and/or substitution product" for -component A) means product consisting of or comprising the complexes of the electron donor compound with the aluminium alkyl compound and the compounds resulting from the reaction of an aluminium trialkyl compounds with an electron donor compound containing mobile hydrogen atoms that are capable o~ reacting with the aluminium trialkyl to bring about substitution reactions such as, for example:
.
.I CA~ALYSrrS ~ND CAT~LYST ~O~II'ON~NTS ~OI~ POLYMEI~IZING
OLE~INSI~
in the namc of Montedison S.p.A.~ ~lan, (Italy), .
*~ *~
This invention relates to catalyst components for polymer_ izin~ ole~ins comprising compounds containing Ti, Mg and halogens, to the catalysts obtained by reacting such com-ponents with Al metallorganic compounds, and to processes for polymerizin~ olefins in which such catalysts are emplo~
ed.
From Italian patent No. ~32,438 in the name of the Applicant, catalysts are known suited to the polymerization of alpha-ole fins and propylene in particular, which are provided with a high activity and a good stereo~pecificity, consisting of the pro-duct of the reaction between an aluminium alkyl, partially com plexed with a Lewis base, and a solid catalyst component com-p~ising compounds of at least Ti, k~r and optionally complexed with a Lewis base.
. ,-Such catalyst components are generally prepared by grinding a mixture of a Ti halogenated compound with a Mg halide and a Lewis base. The Ti compound may be employed in the form of a complex previously prepared with the Lewis base.
',' ! 1 . . , ~ . . .
.
In order to ob~ain good resul~s from the catalysts obtained from these components, it is necessary that the Mg halide is present in a particularly activated form.
If one tries to employ, in the above-mentioned catalyst components, a Mg halide in the activated form, obtained, by reaction of a Mg alcoholate with a Ti halogenated compound (for example TiCl4), catalysts are obtained, by reaction with aluminium alkyls, which exhibit not quite ;~
satisfactory activity and s~ereospecificity, Analogously, if the magnesium halide in activated form is prepared by reacting a compound of formula RMgX (in which R is a hydrocarbon radical and X may be like R or a halogen) with a Ti halogenated compound, the-solid com~onents thus obtained provide, by reaction with aluminium alkyls, catalysts exhibiting not very high acti~ity and stereoregularity.
It has now surprisingly been found that it is possible to polymerize alpha olefins like propylene, butene-l, with catalysts exhibiting good characteristics of activity .
and stereoregularity, even starting from a catalyst component prepared from organic magnesium compounds including the RMgX
compounds and the magnesium alcoholates.
In the case of the polymerization of ethylene, it has been found that sald catalysts provide polymers whose particle size is comprised in a very narrow range.
The catalysts according to the present invention comprise the product of the reaction of:
A~ an addition and/or substitutlon product of an : ' t~ electron-donor compound ~such as a~Lewis base) ~ -2-~- ~m:PG ' ' ~
~ 10~7880~3 wi.th me~allorganic aluminium compound free of halogen atoms bound to the Al atoms, in which product the molar ratio between the electron-donor groups of the electron-donor compound which are reacted with the metallorganic Al compound and the total moles of the Al compound is comprised between 0~01 and 1, with B) a solid component comprising compounds containing ; 10 Ti, Mg and halogens, in which the halogen/Mg atomic ratio is not less than 1, said solid component being prepared by reacting a Ti compound .
with the solid halogenation product obtained by reaction of a halogenating agent, different from the halogenated Ti compound, with a Mg compound - selected from the group consisting of:
b.l) organic oxygenated magnesium compounds oontaining.at least a Mg-0-R linkage whereLn R is an alkyl- or cycloalkyl-radical containing up to ~, ~
20:~: 20 carbon atoms;
~ b.2)~ metallorganic Mg compounds containing at - : . .. .
~ least a Mg-R linkage wherein R is an alkyl-, : ::
: - ~ cycloalkyl- or aryl- radical containing up to 20 carbon atoms;
b.3) Mg compound~s containing at least a Mg- ~ R' : linkage, wherein~:R and R' may be H or alkyl- or aryl-radicals, ~ sald solid component being further characterized in that it :~ : comprises an electron-donor compound ~such as a Lewis base) :
. _3 ~, .
.
0~78~
in c~uanl:it~ nol: more than 1 mole per g-atom oE Mg.
The texm " addition and/or substitution product" for -component A) means product consisting of or comprising the complexes of the electron donor compound with the aluminium alkyl compound and the compounds resulting from the reaction of an aluminium trialkyl compounds with an electron donor compound containing mobile hydrogen atoms that are capable o~ reacting with the aluminium trialkyl to bring about substitution reactions such as, for example:
2 AIRg ~ R'NH2 -~ R2Al - I ~ AIR2 ~ 2 RH
Any electron donor compound (such as a Lewis base) can be used for preparing the addition and/or substitution compounds with the aluminium alkyl compounds.
Compounds employable to such purpose are amines, amides, ethers, esters, ketones, nitriles, phosphines, stibines, arsines, phosphoramides, thioethers, aldehydes, alcoholates and the organic acid salts of metals belonging to the first four Groups of the Periodic System.
.
~he most interesting results, as regards both activity and stereospeclficity, are achieved when using èsters o~ carboxylic acids or diamines, and particularly the esters of aromatic acids.
Some typical examples of such compounds are: methyl-and ethyl-benzoate, methyl- and ethyl-p-methoxybenzoate, - diethylcarbonate, ethylacetate, dimethylmaleate, tréethylborate, ethyl-o-chlorobenzoate, ethyl-naphthenate, ethyl-toluate, ethyl-p-butoxybenzoate, ehtyl-cyclohexanoate, ethyl-pivalate, N,N,N', N'-tetramethylendiamine, 1,2,4-trimethylpiperazine, ;
-4- `
~.; .
-bm: P6 , ., ` .. - . . . . ...... .... . .... ; ..... ..... .. ... .. .. . . . . .
. ~ .. -. i .. ~ -. ~ .. . .. .. ...
8~
2,5-dimethylpip~r~zine and the like.
The Lewis base~aluminium trialkyl ra~io is generally lower than 1 and, in the case of esters or diamines it ranges from 0.1 to 0.8, and more particularly from 0.2 to 0.4.
Generally, the activity and stereospecificity of the catalysts are aff2cted, in an opposed way, by the Lewis base/aluminium alkyl molar ratio, in the sense that the higher such ratio, the lower the activity and vice-versa as regards the stereospecificity.
The aluminium alkyl compounds to be employed according to the present invention may be selected from a wide range of compounds.
Particularly suited compounds are the aluminium - trialkyls containing linear- or branched-chain alkyls containing up to 20 carbon atoms or products of the reaction of same with water, ammonia or primary amines and containing therefore two or more aluminium atoms bound to one another by oxygen or nitrogen atoms.
Some typical examples of such compounds are: triethyl 2~0; aluminium, trimethyl aluminium, tri-n-butyl aluminium, tri-i-butyl aluminium tri-n-propyl aluminium, triisohexyl ~aIuminium, triisooctyl aluminium, Al(C,2Hz5) 3 ~ (CzH~)zAl-0-Al-(C2X,)2, (C2H5)zAl- -AltC2H,j 2~ isoprenyl aluminium and the like.
6H, Aluminium alkyl compounds containing one alkoxy group can be used.
The ~atalyst according to~this invention may be pr~pared according to various methods. The preferred one consists in prereacting the electron-donor with the aluminium . . -, , , , . , ~ . : : ~: :
, , .- : ~ ., : ~ ., . - ., , ~:
-- ~7~80l3 alkyl compound, for a certain time, generally less than 1 hour, and then adding component A) thus obtained to the component B).
The aluminium alkyl compound, the electron-donor and the component B) can be mixed simultaneously. Another method consists in reacting the aluminium alkyl compound wi-th a mixture of component B) with the electron-donor. In all these cases the electron donor/aluminium alkyl molar ratio is such that between 1% and 100% and preferably between 20~ and 40~ of the Al alkyl compound is combined with the electron-donor.
The Al/Ti atomic ratio in the catalyst is higher -than 1 and can reach value as high as 10,000, preferably comprised between 10 and 200.
The halogenating agents suitable for the preparation of the catalyst of this invention are different from the halogenated Ti compounds, are liquid or gaseous under the reaction conditions and are able to react with the initial magnesium compound so that the halogen atoms became bonded to the Mg atoms.
Halogenating agents which are particularly suitable include hydrogen halides, for instance hydrogenchloride, phosphor pentachloride, thionyl chloride, thionyl bromide, sulfuryl ..chloride, phosgene nitrosyl chloride, the halides of organic and mineral acids. The halogens themseleves may also be used ~:
successfully.
Particularly suitable are the silicon compound .
.selected from the compounds having formula XmSiRn, in which X is a halogen, R an alkyl, ~ycloalkyl, aryl radical containing . 1 to 20 carbon atoms l ' ~ 6-~ ~378~
n + m = 4, 1< m ~ 4 and 0 < n < 3, Typical examples o~ these compounds are silicon ~etrachloride, silicon tetrabromide and chlorosilanes, such -as:
CHgSiCll (CH3)2SiCl2, C~H~SiCl3, (C2H5)zSiCl2~ C3H7SiCl3, .
(CgH7)2SiCl2~ C4H9SiCl3, (C4H9) 2SiC12, trichlorovinylsilane and the like.
It is possible to utilize also products prepared by halogenating polysiloxane, such as, for example, 1,3-dichloro-tetramethyl-disiloxane, 1,5-dichloro-hexamethyl-trisiloxane and 1,7-dichloro~octamethyl-tetrasiloxane.
Also RXn compounds can be used as halogenating agent, wherein R is an hydrocarbon radical, X is halogen, preferably chlorine or bromine, n is an integer from 1 to 10.
Examples of said compounds are carbon tetrachloride, carbon tetrabromide, chloroform, ethylene chloride, 1,1,1-trichloroethane. Good results are obtained also with halogenated metallorganic compounds of Al, like Al(C2H5)2C1, AlC2H,Cl2. Examples of halides of organic and inorganic acids are BCl3, SbCls; benzoyl chloride, acetyl chloride.
In the case the halogenation of a Mg alcoholate with a halide of organic acid, it is useful that the reaction be carried out in the presence of a halogenated Si compound.
Magnesium compounds suitable for the preparation of the catalyst include:
- Mg dialkoxides for instance Mg(OC2H,)z, Mg(OC9H,n.)~, Mg(O-CgH,i.) " Mg(0-C4H9n.)z, Mg(OC4H9i.)~, - Mg monoalkoxides,~for example the Mg-alkyl-alkoxides, or compounds of the formula XMgOR in which X is halogen or .~S04)~5~ OH, (C03)~, (P04 j~
.
- _7_ - . . .. . .
788(3 8 - Mg enolates as Mg acetylacetonate - Grignard compounds, for example ClMgCzH~, ClMgC4H9n.
- MgR2 compounds like Mg(C2H~) 21 Mg(c6Hq) 2-The Mg alcoholates can be used also in form ofcomplexes with different metal alcoholates, for example LiMg(OC3H,i.)3, MgAl(OC3H7i.) 5 .
Mixtures of said Mg compounds with inert organic or inorganic substances can be employed.
Any electron-donor compound can be used to prepare component B).
The electron~donor compounds are preferably selected from amongst the esters of inorganic and organic oxygenated acids and the polyamines. Typical examples of such compounds are the esters of aromatic carboxylic acids, such as benzoic acid, p-methoxybenzoic acid and p-toluic acid and particularly the alkyl esters of said acid; the alkylenediamines~
such as, for example, N7, N", N"', N"" tetramethylethylenediamine.
As electron-donor it is possible to profitably employ also silicon compounds, such as, fcr instance, vinyl-tris(beta-.
~20 methoxyethoxy) silane or gamma-methacryloxypropyl-tris-;~ methoxysilane.
~ ~ . - ..
The electron-donor can be formed in situ during the halogenation reaction. For example the halogenation reaction of a Mg alcoholate with a halogenated Si compound can be carried in presence of a halide of an organic acid, in particular of an aromatic acid such as benzoyl chloride, which forms Lewis base by reaction with the compound of Mg and/or Si.
The titanium compounds to be used according to this invention are-selected in particular from the halogenated -, pG- ' , .. ~ . .; , . . . . .. .. . . . .. . . . .
: . , . . . : . , .- : ~ .: . , . ::
7138V~3 -compounds of t~travalent Ti including the halides and haloalcoholates. Non~halogenated tetravalent Ti compounds can also be used. Examples are the Ti tetra-alcoholates and Ti-tetrachloride and tetramide.
The titanium compound may be added during the reaction of the Mg compound with the halogenating agent when it is a titanium alcoholate such as, for example, Ti(o-iC3H7)~r Ti(O-nC3H,)4, Ti(o-iC4H~)4, Ti(O-nC~Hg)4, Ti(O-C6H5)~, Ti20(o-iC3H7) 6 and the like. Preferably the Ti compound is contacted with the prehalogenated ~g compound.
; The reaction between the magnesium compound and the halogenating agent may be conducted either in the presence or not of hydrocarbon solvents, at temperatures ranging from -15C
to 200~C and preferably from 50C to 150C. If it is operated in the presence of solvents, it is preferable to use high-boiling hydrocarbons (100-170C), in particular iso-paraf-fins containing more than 10 carbon atoms.
It has been found that the best results concerning the actlvity and stereospecificity of the catalyst are 20 obtained when the halogenation product shows a X-ray spectrum comprising a halo whose maximum intensity is shifted with respect to the maximum intensity line present in the spectrum of the ~g dlhalides. In the case of MgCl2 the maximum intensity line is located at an interplanar distance d of 2.56 O
A for rhombohedrical MgCl2 and 2.75 A for hexagonal MgCl2.
~alogenation products having said characteristics can be obtained by reacting for more than 3 hrs, the Mg compounds with SiCl4 at temperature ranging from 60 to 100C.
_9_ bm;P~
.... , . . . . , ~ . . .. . . .
7~38~8 During the halogenation r~action, generally it is operated with halogen/magnesium atomic ratios higher than 2:1, The electron-donor can be added to the Mg compound before, during or after ~he halogenation reaction. The Mg compound electron-donor molar ratios are equal to or higher than 1 and preferably between 2 and 10.
The reaction of the halogenated Mg compound with the Ti compound is c~nducted at temperature ranging in general from 20C to 150C. More particularly when TiCl~ is used, it is pre~erable to carry out the reaction by suspending the halo-genated M~ compound in TiC14 and heating this suspension at temperat~re between 20 and 136C.
The Ti/Mg atomic ratio in the reaction of the Ti compound with the halogenated Mg compound is higher than 1 and preferably comprised between 2 and 50.
According to a preferred embodiment of the present invention the Mg compound and the halogenating agent are reacted in the presence of the Lewis base, operating at a :~
temperature ranging from 50 to 170C.
The reaction product is then treated with a strong ~ excess of TiCl4 operating at a temperature ranging from 6.0 to .
the boiling point of TiCl4 (136C); after removal at temperature higher than 50C the TiCl4 in excess and washing with a hydrocarbon solvent to eliminate the unreacted TiCl4, the solid catalyst component is obtained.
It has been found, besides, -and this is another feature of the present invention - that it is possible to further improve the activity of the catalysts according to this invention, if the preparation of component B) of the , -~0-.' hn:~J~, , C3781!3~3 . catalyst is conduc-ted in the presence o~ a silicon aompound, - either polymeric or not, containing the group - R~ -- sio -Rn .
in which Rl and R" are hydrocarbon radicals, either like orunlike each other, selected in particular from the alkyl radicals containing 1 to 6 C and from the aryl radicais -~ .
containing 6 to 10 C, or R' is hydrogen.
The silicon compound may be employed both during the reaction between Mg compounds and halogenated Si compound, and after such reaction (before or after the reaction with the Ti compound).
. The Mg/Si atomic ratio is generally lower than 2, preferably ranging from 0.1 to 1.
The catalysts according to the invention may be used to polymerize ethylene or alpha-olefins containing at least three carbon atoms:, such as propylene, butene-l, 4-methylpentene-l and the like; or to copolymerize propylene, 20:~ ~or other higher olefins with one another and/or with smaller amounts of ethylene. . : . :
When ethylen~ is to be polymerized, it is convenient to use instead of component A, an aluminium alkyl compound such as al-trialkyl or an alkyl aluminium halide not complexed with the electron-donor.
The polymerization conditions are well known to those skilled in the Art and comprise temperatures ranging from -80C
to ~150C, preferably from 40C to 100C, at partial pressures --11-- .
.,, bm: ~ ` ' - :
1~7880 8 . .
o~ the alpha-olefins higher than the atomspheric pressure.
Polymerization m~y be conducted both in a liquid phase, either in the presence or in the absence of an inert hydrocarbon diluent, and in a gas phase. .
Particularly good results are achieved, in the polymerization of propylene, by operating in the presence of an aliphatic or aromatic inert hydrocarbon diluent, liquid under the polymerization conditions, or by operating in liquid propylene as reaction medium.
The following examples are given to better illustrate the main features of the present industrial invention, without being however a limitation thereof.
In the following examples the melt-flow index (MIL) was determined according to method ASTM D-1238/73; the flexural rigidity was measured according to method ASTM D-747/70 on specimens prepared by molding in a plate press at 200C and by annealing for 2 hours at 140C.
The apparent density, always determined on the polymer in powder form, the intrinsic viscosity and the surface area are measured, conversely, according to known standardized methods.
, , '' EX~PLE 1 -a) Pre~aration of the catalyst 13.91 g of Mg(OC2Hg) 2 wère mixed with 29.8 g o~ ~-methacryIoxypropyl-trimethoxy-silane and 40.8 g of SiCl4 at 62C for 1.5 hours.
The resulting product was treated with 240 ml of TiCl4 a~t 136C for 1.5 hours. The products dissolved in TiCl~ were removed in hot conditions by decantation .
bm: t~6~
~ 78808 f and siphoning. The solid xesidue was treated again with 240 ml of fresh TiCl4 at 136C for 30 minutes.
After hot-removal, by decan~ation and filtration, of the TiCl4, the solid residue was repeatedly washed with n-hexane to eliminate TiC14 in excess.
It was dried under vacuum at 55C, thus obtaining a solid product, whose elemental analysis yielded the following results:
Mg = 12.2% by weight, Ti = 3.6~ by weight, Cl = 52.6~ by weight.
b) Polymerization of propylene in a solvent 217 mg of the solid product (example la) were introduced into a stainless steel autoclave, having a 2.5 1 capacity and containing 1 1 of n-heptane and 1.135 g of Al(C2H5) 3 premixed with 572 mg of ethylanisate.
Polymerization was conducted at 60~C at a pressure of 5 kg/cm2 gauge with propylene and hydrogen 20 ~ (1.5~ by vol. of the gas phase) for 5~hours.
The~presence was kept constant by continuous feedlng of propylene.
At the conclusion, after removal of the solvent by stripping with vapour, 314 g of dry polypropylene in particle-form were obtained, with a yield of 40,200-g of polymer/g of Ti, having a residue ~ to~the extraction with boiling heptane of 89,5~, The polymer was also characterized by the following properties:
.. , . .... , ~,, .. . ~ .... . . . .
788~)8 .
., . ..
- bulk density 0.41 kg/L
- intrinsic viscosity 2.3 dl/g - melt-flow index 1.3 g/10' - flexural rigidity 12,200 kg/cm2.
c~ Polymerization of propylene in a liquid monomer 10 kg of propylene, 12.5 g of Al~C2H,) 3 in 90 ml of n~heptane, 7.2 g of ethylanisate in 120 ml of n-heptane, 720 mg of the solid product prepared according .
to example la) in 130 ml of n-heptane and 15 Nl of hydrogen were introduced into a stainless steel autoclave `
having a capacity of 30 1, The polymerization temperature was brought to 65C and the pressure was adjusted at 26.5 kg/cm2g.
After 5 hours, once the propylene in excess had been removed, 2.85 kg of polypropylene in particle-form were obtained, with a yield of llO,000 g of polymer/g of Ti, having a residue to the extraction with boiling heptane equal to 88.5%.
The polymer was furthermore characterized by the following propertles: . :
- bulk apparent density 0.40 kg/l .
- intrinsic viscosity 1.9 dl/g - melt-flow index 3.2 g/10' - flexural rigidity 12,755 kg/cm~
The above-described polymerization test tlc) was repeated, but using 7.74 g of ethylanisate and 730 . mg of the solid product prepared according to example la).
- The following results were obtained:
.
1~ .
7 ~
- yield 72,300 g of polymer/g of Ti, - residue to the ex-traction in boiling heptane 90.5%.
~ he polypropylene obtained in particle-form was also characterized by the following properties:
- bulk density 0.35 kg/1 - intrinsic viscosity 1.7 dl!g - melt-flow index 5.7 g/lO' - flexural rigidity 14,130 kg/cm2.
d) Polymeriz _ion o~ ethylene in a solvent 20.3 mg of the solid product prepared according to example l a) were introduced into a stainless steel, 2.5-liter autoclave containing l l of n-hexane and 2 g of Al(i C4H~) 3 .
Polymerization was conducted at 85C at a partial pressure of ethylene of 6 kg/cm2g. and at a partial pressure of hydrogen of 7 kg/cm2 g. for 4 hours.
At the conclusion, after evaporation of the solvent in hot conditions and under vacuum, 284 g of ~; polyethylene:in particle-form, free from powder, were obtained, the yield being of 340,000 g of polymer~g ., :: of Ti~
Besides, the polymer was characterized by the following properties:
bulk density 0,37 kg/l - particles average diameter 354 - E grade 27.6 : :, ~i ~ ' , . ,:,' :' . ' ... . .. . . .. . :.. :.. ... ,, .. .,., .- .. ~.. . :,. , . . . : .. . ... .
788~8 a) Pre~aration of the catalyst 27.7 g of Mg(OC2~)2 were treated with 30,6 g o* SiCl4 and 3.37 g of C6H5COCl; this mixture was ;
gradually heated to 155C and kept at such temperature for 2.5 hours.
The resulting semi-solid product was heat-treated, at 136C, with 240 ml of TiC14 for 1.5 hours.
The products dissolved in TiC14 were removed in hot conditions by filtering and successive washing with 200 ml of n-hexane.
The residual solid product was treated again with 200 ml of boiling TiCl4 for 1 hour. Subsequently it was operated as in example la). -The elemental analysis of the solid product thus obtained yielded the following results: ;
Mg = 16.45~ by weight, Ti = 2.70% by weight, Cl = 58.15% by weight.
b) Polymerization of propylene in a solvent It was operated as in example lb), using 234 mg of the solid product prepared according to example 2a), 1.135 g of Al(C2H~) and 572 mg of ethylanisate.
245 g of dry polymer, having a residue of 92%
to the extraction with boiling heptane, were thus obtained, the yield being of 38,800 g of polypropylene/g of Ti in 5 hours.
.
This polymer was characterized furthermore by the following properties:
. bm~, .. . :
: , 7 ~
- bulk density 0.45 kg/l - inkrinsic viscosity 2 dl/g - melt~flow index 5.1 g/10' - flexural rigidity 13,770 kg/cm2 c) Polymerization of propylene in a liquid monomer It was operated as per example lc), employing 12.5 g of Al(C2H5)3, 7.2 g of ethylanisate and 798 mg of the solid product prepared according to example 2a).
In this way, 1.95 kg of polypropylene, having a residue to the extraction with boiling heptane of 91%, were obtained, the yield being of 90,500 g of polymer/g of Ti.
The polymer was also characterized by the following properties:
~ bulk density 0.360 kg/1 - intrinsic viscosity 1.7 dl/g - melt-flow index 4.9 g/10' - flexural rigidity 13,350 kg/cm2.
.;
20 a) Preparation of the catalyst 27.6 g of Mg (OC2Hs) z were mixed with 29 g of trichlorovinylsilan (Cl3Si CHaCH2 ) and 7.2 g of ethylbenzoate.
The mixture was gradually heated and the temperature was kept at 158C for 2 hours. The solid - product thus obtained was thereafter treated with 240 ml of boiling TiCl4 for 2 hours. It was then operated as in example la).
~he elemental analysis of the product so .:
a obtained yielded the following results:
~17-.. . .
bm:~, ~ `
Mg = 18.14% by welght;
Ti - 2.45% by weight;
Cl = 64.4 % by weight.
b) Pol~merization of propylene in a solvent It was operated as in example lb), using 204 mg of the solid product prepared according to example 3a), 1.135 g of Al(C2H5~ 3 and 572 mg of ethylanisate.
275 g of dry polypropylene were thus obtained, having a residue to the extraction with boiling heptane of 87.5~, the yield being of 55,000 g of polymer/g of Ti.
The polymer was furthermore characteriæed by the following properties:
- bulk density 0.39 kg/l - intrinsic viscosity 1.9 dl/g - melt-flow index 3,2 g/10' - flexural rigidity 11,050 kg/cm2.
c) Polymerization of prop~lene in a li~uid monomer It was operated as in example lc), employing 12;5 g of Al(CzH5) 3, 7.2 g of ethylanisate and 730 mg ~0 of the solid product prepared according to example 3a).
2.5 kg of polypropylene were thus obtained, having a residue to the extraction with boiling heptane of 84%, an intrinsic viscosity of 1.8 dl/g, a melt-flow index of 4.7 g/10' a bulk density of 0.39 kg/l and a flexural rigidity of 10,530 kg/cm2, the yield being of 140,000 g of polymer/g of Ti.
The polymerization test described hereinabove (example 3c) was repeated employing 720 mg of solid component, 12.5 g of Al~C1H,)g and 7.74 g of ethylanisate.
, ;:
bm:~ ~
. . . . .. : . . . . . . ~ . . . . . - ~ . . . .
1~378~8 - ``
.` .
In this way, 1.6 kg of polypropylene, having a residue to the extraction with boiling heptane of 85.5~, were obtained, the yield being of 90,600 g of polymer/g of Ti.
The polymer was furthermore characterized by the following properties:
- bulk density 0.40 kg/l - intrinsic viscosity 1.9 dl/g - melt-flow index 3,4 g/10' - flexural rigidity 11,370 kg/cm2.
a) Preparation of the catalyst 240 ml of a solution in n-heptane containing 16.97 g of dissolved Mg(n-C4Hg) 2 were added to 18.8 ml of a solution containing 22 g of SiCl4 and 3.88 g of ethylbenzoate, in 10 minutes, at room temperature, under stirring. The temperature was then raised to 95C and and kept such for 2 hours.
Successively, further 22 g of SiCl4 were gradually added, heating and stirring being carried on for further 2 hours.
A white microcrystalline precipitate separated by decantation in cold conditions; the overlying solution was siphoned and washings with n-heptane were carried out to remove SiCl~ in excess.
After filtration, the solid residue was treated with 240 ml of boiling TiCl~ for 2 hours.
After hot-filtering, the solid residue was treated again in hot condition for two consecutive times, ` -19-1~7880~3 ,:
and for 1 hour each time, with analogous amounts of TiCl 4 .
After the last hot-filtration, the solid residual product was repeatedly cold-washed with n-hexane to remove any trace of free TiCl 4 .
It was then dried under vacuum at 50C. The elemental analysis of the solid product yielded the following results:
- Mg = 18.8 % by weight;
- Ti = 3 % by weight;
- Cl = 59.85% by weight.
b) Polymerization of propylene in a liquid monomer It was operated as described in example lc), employing 970 mg of the solid product prepared according to example 4a), 12.5 g of Al(C2H5) 3 and 6~ 36 g of ethyl-anisate.
1.12 kg of polypropylene in particle-form, having a particle size comprised in a narrow range, and a residue to the extraction with boiling heptane of 79.5%, ~20 were thus obtained, the yield being of 38,400 g of polymer/g of Ti.
Furthermore, the polymer was c~aracterized by . :
the following properties: ~:
- bulk density 0.31 kg/l .
-- intrinsic viscosity 1.7 dl/g - melt-flow index 5.4 g/10' :-- flexural rigidity 10,000 kg/cm2.
The preceding test was repeated, but using 1.1 g of solid product, 12.5 g of Al~C2H,)g and 7.2 g of - -~0- ' - . :
- .::
7 ~ ~ 8 ethylanis~te: 650 g of polypropylene in particle-form wexe thus obtained, having à particle size comprised in a narrow ran~e and a residue to the extraction with :
boiling heptane of 82.5gol the yield being of 19,700 g of polymer/g of Ti.
The polymer was also characterized by the ~ollowing properties:
- bulk density 0.30 kg/l - intrinsic viscosity 1.5 dl/g "
- melt-flow index 7.8 g/10' - flexural rigidity 11,800 kg/cm2.
c) Polymerization o~ ethylene in a solvent 26.7 mg of the solid product prepared according to example 4a) were introduced into a stainless steel, 25-liter autoclave containing 1 1 of n-hexane and 2 g of Al(i-C4H 9 ) 3 .
It was operated as in example ld) and 255 g of particle-form polyethylene free from powder were ob~ained, the yield being of 318 kg of polymer/g of Ti.
~:~ 20 The ~olymer was furthermore characterized by the following properties: .
- bulk density 0.37 kg/l - particles' average dia. 333 ~ `
- grade E 49.2 g/10' EXAMPLE 5 ~.
a) Preparation of the catalysts 13.88 g of Mg(OC2H5) 2 were mixed with 14.7 g : Cl3SiCzH~ and 6.34 g of vinyl-tris-(beta-methoxy-ethoxy)-silane.
~bm:~
378~
The mixture was gradually heated to 155C
and kept a~ such temperature for 2 hours. After cooling, a semi-solid paste was obtained, that was treated with 240 ml of TiCl4 at 136C for 2 hours. The not reacted TiCl4 was decanted and siphoned in hot conditions. The solid residue was re-treated two consecutive times with boiling TiCll,, every time for 1 hour and with analogous amounts.
By operating according to example la), a solid product was obtained, whose elemental analysis yielded the following results:
Mg = 19.6 % by weight, Ti = 2.85 % by weight, Cl = 68.i5 % by waight.
b) PoLymerization of propylene in a solvent It was operated following example lb), employing 229 mg of the solid product prepared according to example 5a), 1.135 ~ of Al(C2H5) 3 and 572 mg of ethylanisate.
By operating in this way it was possible to obtaln 135 g of polypropylene, having a residue to the extraction with boiling heptane equal to 77.5%, the yield being of 20,700 g of polymer/g of Ti in 5 hours.
c) Polymerization of propylene in a li~uid monomer It was operated following the modalities of - example lc), employing 850 mg of the solid product prepared according to example 5a), 12.5 g of Al(C2H~) 9 ' ' and 7.2 g of ethylanisate, 1.28 kg of polypropylene, having a residue to the extraction with boiling heptane bm:~
, .. , .,,, , ., . , . , . .. . , . .. . . ... , ~ .,. .. ,,, . ... .. . . . , . .. ., .. :
37~8~8 of 85~o I were thus obtained, the yeild heing of 52,800 g of polymer/g of Ti.
The polymer was furthermore characterized by the following properties: `
- bulk density 0.39 kg/l - intrinsic viscosity 1.2 dl/g - melt-flow index 7.5 g/10' - flexural rigidity 11,050 kg/cm2 a) Preparation of the catalyst 13.75 g of Mg(OC2H5)2 were mixed with 19.62 g of Cl3SiC2H5, 3.38 g of benzoyl chloride and 3.38 g of polydimethysiloxane (viscosity: 100 Cst).
The mixture was gradually heated, u~der stirring, to 155C and kept at such temperature for 2 hours.
By operating according to the modalities of example 5a), a solid product was obtained, whose elemental~analysis yielded the following results:
;~ 20 Mg = 21.6 ~ by weight, Ti = 1.25~ by weight, Cl = 68.95~ by weight.
b) Polymerization o~ propylene in a solvent It was operated as in example lb), using 234 mg of the solid product prepared according to example 6a), 1.135 g of Al(C2H3)9 and 572 mg of ethylanisate.
276 g of polypropylene in particle-form, free from powders, were thus obtained, having a residue to the extraction with boiling heptane equal to 86.5%, the yield being of 94,500 g of polymer/g of Ti in 5 hours, ~ . .
~, -23- ``
~ 788f~
The polymer was ~urthermore characterized by the following properties:
- bulk density 0.42 kg/l - intrinsic viscosity 1.9 dl/g - melt-flow index 4.7 g/10' - flexural rigidity 9,760 kg/cm2.
c) Pol~nerization of propylene in a liquid monomer It was operated following example lc), using 815 mg of the solid product prepared according to example 6a), 12.5 g of Al(C2H5) 9 and 7.2 g of ethylanisate. Thus, it was possible to obtain 2.35 kg of particle-form polypropylene free from powder, having a residue to the extraction with boiling heptane of 86%i, the yield being of 230,000 g of polymer/g of Ti.
The polymer was also characterized by the following properties: ;
- bulk density 0.47 kg/l :
- intrinsic viscosity 1.8 dl/g ;
- melt-flow index 3 g/10' - flexural rigidity 10,300 kgjcm2.
.. . . . - .. ..
a) Preparation of the catalyst Example 6a) was repeated, but using 1.68 g ;~
of benzoyl chloride and 13.73 g of polydimethylsiloxane.
A solid product was obtained, whose elemental analysis yielded the following results:
Mg = 19.4 % by weight;
Ti = 1. 55% by welght;
Cl = 65~i by weight.
88q~
b) Polymer.ization o~ propylene in a solvent It was operated as in example lb), using 221 mg of the solid product prepared according to example 7a), 1.135 g of Al(C2H~) 3 and 572 mg of ethylanisate.
Z70 g of particle-form polypropylene, free from powder, having a residue to the extraction with boiling heptane of 81.5%, were thus obtained, the yield being of 78,800 g of polymer/g of Ti in 5 hours.
The polymer exhibited also the following properties:
- bulk density 0.44 kg/l - intrinsic viscosity 1.3 dl/g - melt-flow index 13.2 g/10' - flexural rigidity 13,500 kg/cm2.
c) Polymerization of propylene in a liquid monomer It was operated following the modalities of exampLe lc), employing 740 mg of the solid product prepared according to example 7a), 12.5 g of Al(C2H,) 3 :
and 7.2 g of ehtylanisate. In this way, 1.67 kg of a particle-form polypropylene, free from powder, having .
a residue to the extraction with boiling heptane of 87.5~, were obtained, the yield being of 145,500 g of polymer/g of Ti.
The polymer was furthermore characterized by the following properties:
.
- bulk density 0.41 kg/l : - intrinsic viscosity 1.5 dl/g . ~ -melt-flow index 9 g/10' - flexural rigidity 14,700 kg/cm~.
~ -25-~~ -~m:~
~ ~788~)8 ~ ~ ., a) Preparation of the catalyst 19. 6 g Of Cl3SiC2~1s were admixed to 13.73 g of Mg(OC2H5)2. The resulting mixture was gradually heated to 145C, and kept at such temperature for 2 hours under stirring. The semi-fluid paste so obtained was repeatedly washed at 68C with n-hexane by decantation.
The solid suspended in 50 ml of n-hexane was added with l.Bl g of ethyl benzoate and 1.81 g of polydimethylsiloxane (viscosity = 100 cst.).
The mixture was heated to 70C and kept at such temperature for 1 hour. It was evaporated under a moderate vacuum at 50C, and the solid residue obtained -was treated with 240 ml of boiling TiCl4 for 2 hours.
After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid residual. After several washings in hot conditions (68C) with n-hexane, it was filtered under vacuum at 60C.
A solid product was so obtained, whose elemental analysis yielded the following results:
Mg - 17.16~ by weight, . :' Ti = 2.2 ~ by weight, - Cl = 60.65% by weight.
b) Polymerization of pro~lene in a solvent It was operated following example lb), employing 187 mg of the =olid product prepared according to example 8a), 1.135 g of Al(C2H5) 3 and 572 mg of ethylanisate. In this way it was possible to obtain 165 g of particle-form dry polypropylene, having a residue to the extraction bm:~
. - - -~ - . - ,, - - ~ : ,, ,, .; . . ... .. -: .. : . .
~07880B
, ..
with boiling heptane of 86.5~, the yield being of 40,2~0 g of pol~iner/g o~ Ti Thie polymer was furthermore characterized by the following properties:
- bulk density 0.40 kg/l - intrinsic viscosity 1.6 dl/g - melt-flow index 8.4 g/10' - flexural rigidity 11,880 kg/cm2.
c) Polymerization of propylene in a liquid monomer It was operated as in example lc), using 740 mg of the solid product prepared according to example 8a), 12.5 g of Al(C2H~) 3 and 7.2 g of ethylanisate. In this way, 1.35 kg of particle-form polypropylene, having a residue to the extraction with boiling heptaine of 87~, were obtained, the yield being of 82,800 g of polymer/g of Ti. The polymer was furthermore characterized by the following properties:
- bulk density 0.41 kg/l ~ intrinsic viscosity1.4 dl/g - melt-flow index 5.6 g/10' - flexural rigidity11,850 kg/cm2.
EXA~IPLE 9 Example 7b) was repeated but using 155 mg of the solid catalyst component prepared according to example 7a), 1,135 g of Al(C2H5) 3 and 640 mg of ethylanisate.
- In this case, the polymerization was effected in n-heptane under a pressure of 10 kg/cm2 gauge (lo 5~ by volume of hydrogen in the gas phase) for 6 hours.
`~ ~078~
In this way 260 g of polypropylene were obtained in "particle form" ~ree from powder, with a yield of 108,000 g of polymer/g of Ti, having a residue to extraction with boiling heptane o~ 85%, a bulk density of 0.45 kg/l, a melt-flow-index of 13.7 g/10' and a flexural rigidity of 12,440 kg/cm2.
~XAMPLE 10 a) Preparation of the catalyst 19.6 g of SnCl4 were admixed to 13.73 g of Mg(OC2H,) 2. The resulting mixture was gradually heated to 145C, and kept at such temperature for 2 hours under stirring. The semi-fluid paste so obtained was repeatedly washed at 68C with n-hexane by decantation.
The solid suspended in 50 ml of n-hexane was ~-added with 1.81 g of ethyl ben~oate and 1.81 g of polydimethylsiloxane ~viscosity = 100 cst.).
The mixture was heated to 70C and kept at such temperature for 1 hour. It was evaporated under a moderate vacuum at 50C, and the solid residue ohtained was treated with 240 ml of boiling TiCl4 for 2 hours. ;
After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid residual. After several washings in hot conditions (68C) with n-hexane, it was filtered under vacuum at 60C.
b) Polymerization of propylene in a solvent It was operated following example lb), employing 197 mg of the solid product prepared according to example - 10 a), 1.135 g of Al(C2H,) 3 and 572 mg of ethylanisate.
In this way it was possible to obtain 170 g of dry , :, ..
~ 37~
pol~propylene, having a residue to the extrac~ion with boiliny heptana of 85%.
The polymer was furthermore characterized by the following properties:
- bulk density 0.41 kg/l - intrinsic viscosity 1.6 dl/g :.
- melt-flow index 8.4 g/10' - flexural rigidity 11,880 kg/cm2.
c) Polymerization of propylene in a liquid monomer It was operated as in example lc), using 780 mg of the solid product prepared according to example 10 a), 12.5 g of Al(C2H5) 3 and 7.2 g of ethylanisate.
In this way, 1.40 kg of polypropylene, having a residue to the extraction with boiling heptane of 85~, were obtained.
The polymer was furthermore characterized by the following properties:
- bulk density 0,42 kg/l - intrinsic viscosity 1.4 dl/g ..
- melt-flow index 5.6 g/10' - flexural rigidity 11,850 kg/cm2.
a) Preparation of the catalyst 119 g SOCl2 were admixed to 11.45 g of Mg(OC2H~) 2 . The resulting mixture was gradually heated to 60C, and kept at such temperature for 2 hours under stirring. The excess SOCl 2 was removed and the solid product so obtained was repeatedly washed at 68~C with n-hexane by decantation.
: -29-.'' , : '' ' , ' . ' ' , :. ' ' ' ' ~V7~3808 The solid suspended in 100 ml of n-hexane was added with 3 g of e~hyl benzoate and 1.81 g o~
polydimethylsiloxane (viscosity = 100 cst.).
The mixture was heated to 70C and kept at such temperature for 1 hour. It was evaporated under a moderate vacuum at 50C, and the solid residue obtained was treated with 240 ml of boiling TiCl4 for 2 hours.
After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid residual. After several washings in hot conditions ~68C) with n-hexane, it was filtered under vacuum at '':.:
60~C.
b) Polymerization of propylene in a solvent -It was operated following example lb), employing 190 mg of the solid product prepared according to example lla), 1.135 g of Al(C2H5) 3 and 572 mg of ethylanisate.
In this way it was possible to obtain 168 g of polypropylene, having a residue to the extraction with boiling heptane of 84~.
20 ~ The polymer was furthermore characterized by the following properties:
- bulk density 0.39 kg/l - intrinsic viscosity 1.6 dl/g - melt-flow index 8.4 g/10' - flexural rigidity 11,880 kg/cm2.
c) Polymerization of ~ropylene in a liquid monomer It was operated as in example lc), using 770 mg of the solid product prepared according to example lla), 12.5 g of AI(CzH,) 3 and 7.2 g of ethylanisate. In this bm~
~378808 ..
.
way, 1.3 kg of particle-form polypropylene, having a residue to the extraction with boiling heptane of 85%
were obtained.
The polymer was furthermore characterized by the following proper~ies:
- bulk density 0.40 kg/l - intrinsic viscosity1.4 dl/g - melt-flow index 5.6 g/10' - flexural rigidity11,880 kg/cm2.
a) Preparation of the catalyst 11.45 g of Mg(OC~H5) 2 were admixed with 200 ml of n-hexane and 3 g of ethyl benzoate. In the resulting mixture kept at 0C, gaseous anhydrous HCl was bubbled for 1 hour.
The solid product so obtained was filtered and repeatedly washed at 0C with n-hexane till complete removal of HCl and then was treated with 240 ml of boiling TiCl4 for 2 hours.
~ After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid ~:
residual.
After several washings in hot conditions (68C) with n-hexane, it was filtered under vacuum at 60C.
b) Polymerization of propylene in a solvent Tt was operated following example lb), employing~l85 mg of the solid product prepared according to example 12a) 1.135 g of Al(C2H,) 3 and 572 mg of ethylanisate. In this way it was possible to obtain ,.
~.
bm: ~
~'78~3~8.
160 g of polypropylene, having a residue to the ex~rac~ion with boiling heptane of 86%. ~
The polymer was furthermore characterized by ~ -the following properties:
- bulk density 0.40 kg/l - intrinsic viscosity1.6 dl/g - melt-flow index 8.4 g/10' - flexural rigidity11,880 kg/cm2.
c) Polymerization of propylene in a li~uid monomer It was operated as in example lc), using 735 mg of the solid product prepared according to example 12a), 12.5 g of Al(C2H5) 3 and 7.2 g of ethylanisate. In this way, 1.3 kg of polypropylene, having a residue to the extraction with boiling heptane of 87~, were obtained.
The polymer was furthermore characterized by the following properties:
- bulk density 0.41 kg/l - intrinsic viscosity1.4 dl/g - melt-flow index 5.6 g/10' - flexural rigidity11,850 kg/cm2.
a~ Preparation of the catalyst -.
4 g of ClMgN(C4H9) 2 were reacted in an inert gas atmosphere with a solution contain mg 0.615 ml of ethyl benzoate in 20 ml of SiC14 at 65C under stirring for 24 hours.
. .
~he resulting white solid was filtered, washed with 200 ml of desulphurized anhydrous n-heptane, dried and reacted with 50 ml .
of TiCl4 at 130C for 2 hours under stirring. TiCl4 was removed by filtration and further 50 ml of same were added;
.
- bm: ~
~ 788~3 .
the whole was allowed to react for urkher 2 hours at 13~C, whereupon it was filtered and washed at 80C with 300 ml of n-heptane. The solid thus obtained revealed, on analysis, a Ti content equal to 2,17~ by weight and ~ Cl content of 68%.
b) Polymerization of propylene in a solvent 5 millimoles (1 g) of aluminium triisobutyl were reacted at room temperature with 1.25 millimoles (187 mg) of methyl para-toluate in 80 ml of anhydrous desulphurized n-heptane for 5 minutes.
50 ml of such solution were contacted with a suitable amo`unt of the catalyst component prepared as described hereinabove.
The remaining 30 ml were diluted to 1,000 ml with n-heptane and introduced, under a nitrogen pressure, into a steel atuoclave equipped with stirrer, thermoregulated at 40C, whereinto propylene was made to flow.
In the same way the catalytic component suspension was then introduced. After closing of the autoclave, hydrogen was added up to a partial pressure of 0.1 atm., and then it was heated to 60~C under contemporaneous feeding of propylene up to a totaI pressure of 5 atmospheresO Such pressure was kept constant throughout the polymerization by going on feeding the monomer. After 4 hours the polymerization was stopped and the polypropylene was isolated by treating it with methanol and acetone.
.
The results of the polymerization test are reported on Table 1.
Any electron donor compound (such as a Lewis base) can be used for preparing the addition and/or substitution compounds with the aluminium alkyl compounds.
Compounds employable to such purpose are amines, amides, ethers, esters, ketones, nitriles, phosphines, stibines, arsines, phosphoramides, thioethers, aldehydes, alcoholates and the organic acid salts of metals belonging to the first four Groups of the Periodic System.
.
~he most interesting results, as regards both activity and stereospeclficity, are achieved when using èsters o~ carboxylic acids or diamines, and particularly the esters of aromatic acids.
Some typical examples of such compounds are: methyl-and ethyl-benzoate, methyl- and ethyl-p-methoxybenzoate, - diethylcarbonate, ethylacetate, dimethylmaleate, tréethylborate, ethyl-o-chlorobenzoate, ethyl-naphthenate, ethyl-toluate, ethyl-p-butoxybenzoate, ehtyl-cyclohexanoate, ethyl-pivalate, N,N,N', N'-tetramethylendiamine, 1,2,4-trimethylpiperazine, ;
-4- `
~.; .
-bm: P6 , ., ` .. - . . . . ...... .... . .... ; ..... ..... .. ... .. .. . . . . .
. ~ .. -. i .. ~ -. ~ .. . .. .. ...
8~
2,5-dimethylpip~r~zine and the like.
The Lewis base~aluminium trialkyl ra~io is generally lower than 1 and, in the case of esters or diamines it ranges from 0.1 to 0.8, and more particularly from 0.2 to 0.4.
Generally, the activity and stereospecificity of the catalysts are aff2cted, in an opposed way, by the Lewis base/aluminium alkyl molar ratio, in the sense that the higher such ratio, the lower the activity and vice-versa as regards the stereospecificity.
The aluminium alkyl compounds to be employed according to the present invention may be selected from a wide range of compounds.
Particularly suited compounds are the aluminium - trialkyls containing linear- or branched-chain alkyls containing up to 20 carbon atoms or products of the reaction of same with water, ammonia or primary amines and containing therefore two or more aluminium atoms bound to one another by oxygen or nitrogen atoms.
Some typical examples of such compounds are: triethyl 2~0; aluminium, trimethyl aluminium, tri-n-butyl aluminium, tri-i-butyl aluminium tri-n-propyl aluminium, triisohexyl ~aIuminium, triisooctyl aluminium, Al(C,2Hz5) 3 ~ (CzH~)zAl-0-Al-(C2X,)2, (C2H5)zAl- -AltC2H,j 2~ isoprenyl aluminium and the like.
6H, Aluminium alkyl compounds containing one alkoxy group can be used.
The ~atalyst according to~this invention may be pr~pared according to various methods. The preferred one consists in prereacting the electron-donor with the aluminium . . -, , , , . , ~ . : : ~: :
, , .- : ~ ., : ~ ., . - ., , ~:
-- ~7~80l3 alkyl compound, for a certain time, generally less than 1 hour, and then adding component A) thus obtained to the component B).
The aluminium alkyl compound, the electron-donor and the component B) can be mixed simultaneously. Another method consists in reacting the aluminium alkyl compound wi-th a mixture of component B) with the electron-donor. In all these cases the electron donor/aluminium alkyl molar ratio is such that between 1% and 100% and preferably between 20~ and 40~ of the Al alkyl compound is combined with the electron-donor.
The Al/Ti atomic ratio in the catalyst is higher -than 1 and can reach value as high as 10,000, preferably comprised between 10 and 200.
The halogenating agents suitable for the preparation of the catalyst of this invention are different from the halogenated Ti compounds, are liquid or gaseous under the reaction conditions and are able to react with the initial magnesium compound so that the halogen atoms became bonded to the Mg atoms.
Halogenating agents which are particularly suitable include hydrogen halides, for instance hydrogenchloride, phosphor pentachloride, thionyl chloride, thionyl bromide, sulfuryl ..chloride, phosgene nitrosyl chloride, the halides of organic and mineral acids. The halogens themseleves may also be used ~:
successfully.
Particularly suitable are the silicon compound .
.selected from the compounds having formula XmSiRn, in which X is a halogen, R an alkyl, ~ycloalkyl, aryl radical containing . 1 to 20 carbon atoms l ' ~ 6-~ ~378~
n + m = 4, 1< m ~ 4 and 0 < n < 3, Typical examples o~ these compounds are silicon ~etrachloride, silicon tetrabromide and chlorosilanes, such -as:
CHgSiCll (CH3)2SiCl2, C~H~SiCl3, (C2H5)zSiCl2~ C3H7SiCl3, .
(CgH7)2SiCl2~ C4H9SiCl3, (C4H9) 2SiC12, trichlorovinylsilane and the like.
It is possible to utilize also products prepared by halogenating polysiloxane, such as, for example, 1,3-dichloro-tetramethyl-disiloxane, 1,5-dichloro-hexamethyl-trisiloxane and 1,7-dichloro~octamethyl-tetrasiloxane.
Also RXn compounds can be used as halogenating agent, wherein R is an hydrocarbon radical, X is halogen, preferably chlorine or bromine, n is an integer from 1 to 10.
Examples of said compounds are carbon tetrachloride, carbon tetrabromide, chloroform, ethylene chloride, 1,1,1-trichloroethane. Good results are obtained also with halogenated metallorganic compounds of Al, like Al(C2H5)2C1, AlC2H,Cl2. Examples of halides of organic and inorganic acids are BCl3, SbCls; benzoyl chloride, acetyl chloride.
In the case the halogenation of a Mg alcoholate with a halide of organic acid, it is useful that the reaction be carried out in the presence of a halogenated Si compound.
Magnesium compounds suitable for the preparation of the catalyst include:
- Mg dialkoxides for instance Mg(OC2H,)z, Mg(OC9H,n.)~, Mg(O-CgH,i.) " Mg(0-C4H9n.)z, Mg(OC4H9i.)~, - Mg monoalkoxides,~for example the Mg-alkyl-alkoxides, or compounds of the formula XMgOR in which X is halogen or .~S04)~5~ OH, (C03)~, (P04 j~
.
- _7_ - . . .. . .
788(3 8 - Mg enolates as Mg acetylacetonate - Grignard compounds, for example ClMgCzH~, ClMgC4H9n.
- MgR2 compounds like Mg(C2H~) 21 Mg(c6Hq) 2-The Mg alcoholates can be used also in form ofcomplexes with different metal alcoholates, for example LiMg(OC3H,i.)3, MgAl(OC3H7i.) 5 .
Mixtures of said Mg compounds with inert organic or inorganic substances can be employed.
Any electron-donor compound can be used to prepare component B).
The electron~donor compounds are preferably selected from amongst the esters of inorganic and organic oxygenated acids and the polyamines. Typical examples of such compounds are the esters of aromatic carboxylic acids, such as benzoic acid, p-methoxybenzoic acid and p-toluic acid and particularly the alkyl esters of said acid; the alkylenediamines~
such as, for example, N7, N", N"', N"" tetramethylethylenediamine.
As electron-donor it is possible to profitably employ also silicon compounds, such as, fcr instance, vinyl-tris(beta-.
~20 methoxyethoxy) silane or gamma-methacryloxypropyl-tris-;~ methoxysilane.
~ ~ . - ..
The electron-donor can be formed in situ during the halogenation reaction. For example the halogenation reaction of a Mg alcoholate with a halogenated Si compound can be carried in presence of a halide of an organic acid, in particular of an aromatic acid such as benzoyl chloride, which forms Lewis base by reaction with the compound of Mg and/or Si.
The titanium compounds to be used according to this invention are-selected in particular from the halogenated -, pG- ' , .. ~ . .; , . . . . .. .. . . . .. . . . .
: . , . . . : . , .- : ~ .: . , . ::
7138V~3 -compounds of t~travalent Ti including the halides and haloalcoholates. Non~halogenated tetravalent Ti compounds can also be used. Examples are the Ti tetra-alcoholates and Ti-tetrachloride and tetramide.
The titanium compound may be added during the reaction of the Mg compound with the halogenating agent when it is a titanium alcoholate such as, for example, Ti(o-iC3H7)~r Ti(O-nC3H,)4, Ti(o-iC4H~)4, Ti(O-nC~Hg)4, Ti(O-C6H5)~, Ti20(o-iC3H7) 6 and the like. Preferably the Ti compound is contacted with the prehalogenated ~g compound.
; The reaction between the magnesium compound and the halogenating agent may be conducted either in the presence or not of hydrocarbon solvents, at temperatures ranging from -15C
to 200~C and preferably from 50C to 150C. If it is operated in the presence of solvents, it is preferable to use high-boiling hydrocarbons (100-170C), in particular iso-paraf-fins containing more than 10 carbon atoms.
It has been found that the best results concerning the actlvity and stereospecificity of the catalyst are 20 obtained when the halogenation product shows a X-ray spectrum comprising a halo whose maximum intensity is shifted with respect to the maximum intensity line present in the spectrum of the ~g dlhalides. In the case of MgCl2 the maximum intensity line is located at an interplanar distance d of 2.56 O
A for rhombohedrical MgCl2 and 2.75 A for hexagonal MgCl2.
~alogenation products having said characteristics can be obtained by reacting for more than 3 hrs, the Mg compounds with SiCl4 at temperature ranging from 60 to 100C.
_9_ bm;P~
.... , . . . . , ~ . . .. . . .
7~38~8 During the halogenation r~action, generally it is operated with halogen/magnesium atomic ratios higher than 2:1, The electron-donor can be added to the Mg compound before, during or after ~he halogenation reaction. The Mg compound electron-donor molar ratios are equal to or higher than 1 and preferably between 2 and 10.
The reaction of the halogenated Mg compound with the Ti compound is c~nducted at temperature ranging in general from 20C to 150C. More particularly when TiCl~ is used, it is pre~erable to carry out the reaction by suspending the halo-genated M~ compound in TiC14 and heating this suspension at temperat~re between 20 and 136C.
The Ti/Mg atomic ratio in the reaction of the Ti compound with the halogenated Mg compound is higher than 1 and preferably comprised between 2 and 50.
According to a preferred embodiment of the present invention the Mg compound and the halogenating agent are reacted in the presence of the Lewis base, operating at a :~
temperature ranging from 50 to 170C.
The reaction product is then treated with a strong ~ excess of TiCl4 operating at a temperature ranging from 6.0 to .
the boiling point of TiCl4 (136C); after removal at temperature higher than 50C the TiCl4 in excess and washing with a hydrocarbon solvent to eliminate the unreacted TiCl4, the solid catalyst component is obtained.
It has been found, besides, -and this is another feature of the present invention - that it is possible to further improve the activity of the catalysts according to this invention, if the preparation of component B) of the , -~0-.' hn:~J~, , C3781!3~3 . catalyst is conduc-ted in the presence o~ a silicon aompound, - either polymeric or not, containing the group - R~ -- sio -Rn .
in which Rl and R" are hydrocarbon radicals, either like orunlike each other, selected in particular from the alkyl radicals containing 1 to 6 C and from the aryl radicais -~ .
containing 6 to 10 C, or R' is hydrogen.
The silicon compound may be employed both during the reaction between Mg compounds and halogenated Si compound, and after such reaction (before or after the reaction with the Ti compound).
. The Mg/Si atomic ratio is generally lower than 2, preferably ranging from 0.1 to 1.
The catalysts according to the invention may be used to polymerize ethylene or alpha-olefins containing at least three carbon atoms:, such as propylene, butene-l, 4-methylpentene-l and the like; or to copolymerize propylene, 20:~ ~or other higher olefins with one another and/or with smaller amounts of ethylene. . : . :
When ethylen~ is to be polymerized, it is convenient to use instead of component A, an aluminium alkyl compound such as al-trialkyl or an alkyl aluminium halide not complexed with the electron-donor.
The polymerization conditions are well known to those skilled in the Art and comprise temperatures ranging from -80C
to ~150C, preferably from 40C to 100C, at partial pressures --11-- .
.,, bm: ~ ` ' - :
1~7880 8 . .
o~ the alpha-olefins higher than the atomspheric pressure.
Polymerization m~y be conducted both in a liquid phase, either in the presence or in the absence of an inert hydrocarbon diluent, and in a gas phase. .
Particularly good results are achieved, in the polymerization of propylene, by operating in the presence of an aliphatic or aromatic inert hydrocarbon diluent, liquid under the polymerization conditions, or by operating in liquid propylene as reaction medium.
The following examples are given to better illustrate the main features of the present industrial invention, without being however a limitation thereof.
In the following examples the melt-flow index (MIL) was determined according to method ASTM D-1238/73; the flexural rigidity was measured according to method ASTM D-747/70 on specimens prepared by molding in a plate press at 200C and by annealing for 2 hours at 140C.
The apparent density, always determined on the polymer in powder form, the intrinsic viscosity and the surface area are measured, conversely, according to known standardized methods.
, , '' EX~PLE 1 -a) Pre~aration of the catalyst 13.91 g of Mg(OC2Hg) 2 wère mixed with 29.8 g o~ ~-methacryIoxypropyl-trimethoxy-silane and 40.8 g of SiCl4 at 62C for 1.5 hours.
The resulting product was treated with 240 ml of TiCl4 a~t 136C for 1.5 hours. The products dissolved in TiCl~ were removed in hot conditions by decantation .
bm: t~6~
~ 78808 f and siphoning. The solid xesidue was treated again with 240 ml of fresh TiCl4 at 136C for 30 minutes.
After hot-removal, by decan~ation and filtration, of the TiCl4, the solid residue was repeatedly washed with n-hexane to eliminate TiC14 in excess.
It was dried under vacuum at 55C, thus obtaining a solid product, whose elemental analysis yielded the following results:
Mg = 12.2% by weight, Ti = 3.6~ by weight, Cl = 52.6~ by weight.
b) Polymerization of propylene in a solvent 217 mg of the solid product (example la) were introduced into a stainless steel autoclave, having a 2.5 1 capacity and containing 1 1 of n-heptane and 1.135 g of Al(C2H5) 3 premixed with 572 mg of ethylanisate.
Polymerization was conducted at 60~C at a pressure of 5 kg/cm2 gauge with propylene and hydrogen 20 ~ (1.5~ by vol. of the gas phase) for 5~hours.
The~presence was kept constant by continuous feedlng of propylene.
At the conclusion, after removal of the solvent by stripping with vapour, 314 g of dry polypropylene in particle-form were obtained, with a yield of 40,200-g of polymer/g of Ti, having a residue ~ to~the extraction with boiling heptane of 89,5~, The polymer was also characterized by the following properties:
.. , . .... , ~,, .. . ~ .... . . . .
788~)8 .
., . ..
- bulk density 0.41 kg/L
- intrinsic viscosity 2.3 dl/g - melt-flow index 1.3 g/10' - flexural rigidity 12,200 kg/cm2.
c~ Polymerization of propylene in a liquid monomer 10 kg of propylene, 12.5 g of Al~C2H,) 3 in 90 ml of n~heptane, 7.2 g of ethylanisate in 120 ml of n-heptane, 720 mg of the solid product prepared according .
to example la) in 130 ml of n-heptane and 15 Nl of hydrogen were introduced into a stainless steel autoclave `
having a capacity of 30 1, The polymerization temperature was brought to 65C and the pressure was adjusted at 26.5 kg/cm2g.
After 5 hours, once the propylene in excess had been removed, 2.85 kg of polypropylene in particle-form were obtained, with a yield of llO,000 g of polymer/g of Ti, having a residue to the extraction with boiling heptane equal to 88.5%.
The polymer was furthermore characterized by the following propertles: . :
- bulk apparent density 0.40 kg/l .
- intrinsic viscosity 1.9 dl/g - melt-flow index 3.2 g/10' - flexural rigidity 12,755 kg/cm~
The above-described polymerization test tlc) was repeated, but using 7.74 g of ethylanisate and 730 . mg of the solid product prepared according to example la).
- The following results were obtained:
.
1~ .
7 ~
- yield 72,300 g of polymer/g of Ti, - residue to the ex-traction in boiling heptane 90.5%.
~ he polypropylene obtained in particle-form was also characterized by the following properties:
- bulk density 0.35 kg/1 - intrinsic viscosity 1.7 dl!g - melt-flow index 5.7 g/lO' - flexural rigidity 14,130 kg/cm2.
d) Polymeriz _ion o~ ethylene in a solvent 20.3 mg of the solid product prepared according to example l a) were introduced into a stainless steel, 2.5-liter autoclave containing l l of n-hexane and 2 g of Al(i C4H~) 3 .
Polymerization was conducted at 85C at a partial pressure of ethylene of 6 kg/cm2g. and at a partial pressure of hydrogen of 7 kg/cm2 g. for 4 hours.
At the conclusion, after evaporation of the solvent in hot conditions and under vacuum, 284 g of ~; polyethylene:in particle-form, free from powder, were obtained, the yield being of 340,000 g of polymer~g ., :: of Ti~
Besides, the polymer was characterized by the following properties:
bulk density 0,37 kg/l - particles average diameter 354 - E grade 27.6 : :, ~i ~ ' , . ,:,' :' . ' ... . .. . . .. . :.. :.. ... ,, .. .,., .- .. ~.. . :,. , . . . : .. . ... .
788~8 a) Pre~aration of the catalyst 27.7 g of Mg(OC2~)2 were treated with 30,6 g o* SiCl4 and 3.37 g of C6H5COCl; this mixture was ;
gradually heated to 155C and kept at such temperature for 2.5 hours.
The resulting semi-solid product was heat-treated, at 136C, with 240 ml of TiC14 for 1.5 hours.
The products dissolved in TiC14 were removed in hot conditions by filtering and successive washing with 200 ml of n-hexane.
The residual solid product was treated again with 200 ml of boiling TiCl4 for 1 hour. Subsequently it was operated as in example la). -The elemental analysis of the solid product thus obtained yielded the following results: ;
Mg = 16.45~ by weight, Ti = 2.70% by weight, Cl = 58.15% by weight.
b) Polymerization of propylene in a solvent It was operated as in example lb), using 234 mg of the solid product prepared according to example 2a), 1.135 g of Al(C2H~) and 572 mg of ethylanisate.
245 g of dry polymer, having a residue of 92%
to the extraction with boiling heptane, were thus obtained, the yield being of 38,800 g of polypropylene/g of Ti in 5 hours.
.
This polymer was characterized furthermore by the following properties:
. bm~, .. . :
: , 7 ~
- bulk density 0.45 kg/l - inkrinsic viscosity 2 dl/g - melt~flow index 5.1 g/10' - flexural rigidity 13,770 kg/cm2 c) Polymerization of propylene in a liquid monomer It was operated as per example lc), employing 12.5 g of Al(C2H5)3, 7.2 g of ethylanisate and 798 mg of the solid product prepared according to example 2a).
In this way, 1.95 kg of polypropylene, having a residue to the extraction with boiling heptane of 91%, were obtained, the yield being of 90,500 g of polymer/g of Ti.
The polymer was also characterized by the following properties:
~ bulk density 0.360 kg/1 - intrinsic viscosity 1.7 dl/g - melt-flow index 4.9 g/10' - flexural rigidity 13,350 kg/cm2.
.;
20 a) Preparation of the catalyst 27.6 g of Mg (OC2Hs) z were mixed with 29 g of trichlorovinylsilan (Cl3Si CHaCH2 ) and 7.2 g of ethylbenzoate.
The mixture was gradually heated and the temperature was kept at 158C for 2 hours. The solid - product thus obtained was thereafter treated with 240 ml of boiling TiCl4 for 2 hours. It was then operated as in example la).
~he elemental analysis of the product so .:
a obtained yielded the following results:
~17-.. . .
bm:~, ~ `
Mg = 18.14% by welght;
Ti - 2.45% by weight;
Cl = 64.4 % by weight.
b) Pol~merization of propylene in a solvent It was operated as in example lb), using 204 mg of the solid product prepared according to example 3a), 1.135 g of Al(C2H5~ 3 and 572 mg of ethylanisate.
275 g of dry polypropylene were thus obtained, having a residue to the extraction with boiling heptane of 87.5~, the yield being of 55,000 g of polymer/g of Ti.
The polymer was furthermore characteriæed by the following properties:
- bulk density 0.39 kg/l - intrinsic viscosity 1.9 dl/g - melt-flow index 3,2 g/10' - flexural rigidity 11,050 kg/cm2.
c) Polymerization of prop~lene in a li~uid monomer It was operated as in example lc), employing 12;5 g of Al(CzH5) 3, 7.2 g of ethylanisate and 730 mg ~0 of the solid product prepared according to example 3a).
2.5 kg of polypropylene were thus obtained, having a residue to the extraction with boiling heptane of 84%, an intrinsic viscosity of 1.8 dl/g, a melt-flow index of 4.7 g/10' a bulk density of 0.39 kg/l and a flexural rigidity of 10,530 kg/cm2, the yield being of 140,000 g of polymer/g of Ti.
The polymerization test described hereinabove (example 3c) was repeated employing 720 mg of solid component, 12.5 g of Al~C1H,)g and 7.74 g of ethylanisate.
, ;:
bm:~ ~
. . . . .. : . . . . . . ~ . . . . . - ~ . . . .
1~378~8 - ``
.` .
In this way, 1.6 kg of polypropylene, having a residue to the extraction with boiling heptane of 85.5~, were obtained, the yield being of 90,600 g of polymer/g of Ti.
The polymer was furthermore characterized by the following properties:
- bulk density 0.40 kg/l - intrinsic viscosity 1.9 dl/g - melt-flow index 3,4 g/10' - flexural rigidity 11,370 kg/cm2.
a) Preparation of the catalyst 240 ml of a solution in n-heptane containing 16.97 g of dissolved Mg(n-C4Hg) 2 were added to 18.8 ml of a solution containing 22 g of SiCl4 and 3.88 g of ethylbenzoate, in 10 minutes, at room temperature, under stirring. The temperature was then raised to 95C and and kept such for 2 hours.
Successively, further 22 g of SiCl4 were gradually added, heating and stirring being carried on for further 2 hours.
A white microcrystalline precipitate separated by decantation in cold conditions; the overlying solution was siphoned and washings with n-heptane were carried out to remove SiCl~ in excess.
After filtration, the solid residue was treated with 240 ml of boiling TiCl~ for 2 hours.
After hot-filtering, the solid residue was treated again in hot condition for two consecutive times, ` -19-1~7880~3 ,:
and for 1 hour each time, with analogous amounts of TiCl 4 .
After the last hot-filtration, the solid residual product was repeatedly cold-washed with n-hexane to remove any trace of free TiCl 4 .
It was then dried under vacuum at 50C. The elemental analysis of the solid product yielded the following results:
- Mg = 18.8 % by weight;
- Ti = 3 % by weight;
- Cl = 59.85% by weight.
b) Polymerization of propylene in a liquid monomer It was operated as described in example lc), employing 970 mg of the solid product prepared according to example 4a), 12.5 g of Al(C2H5) 3 and 6~ 36 g of ethyl-anisate.
1.12 kg of polypropylene in particle-form, having a particle size comprised in a narrow range, and a residue to the extraction with boiling heptane of 79.5%, ~20 were thus obtained, the yield being of 38,400 g of polymer/g of Ti.
Furthermore, the polymer was c~aracterized by . :
the following properties: ~:
- bulk density 0.31 kg/l .
-- intrinsic viscosity 1.7 dl/g - melt-flow index 5.4 g/10' :-- flexural rigidity 10,000 kg/cm2.
The preceding test was repeated, but using 1.1 g of solid product, 12.5 g of Al~C2H,)g and 7.2 g of - -~0- ' - . :
- .::
7 ~ ~ 8 ethylanis~te: 650 g of polypropylene in particle-form wexe thus obtained, having à particle size comprised in a narrow ran~e and a residue to the extraction with :
boiling heptane of 82.5gol the yield being of 19,700 g of polymer/g of Ti.
The polymer was also characterized by the ~ollowing properties:
- bulk density 0.30 kg/l - intrinsic viscosity 1.5 dl/g "
- melt-flow index 7.8 g/10' - flexural rigidity 11,800 kg/cm2.
c) Polymerization o~ ethylene in a solvent 26.7 mg of the solid product prepared according to example 4a) were introduced into a stainless steel, 25-liter autoclave containing 1 1 of n-hexane and 2 g of Al(i-C4H 9 ) 3 .
It was operated as in example ld) and 255 g of particle-form polyethylene free from powder were ob~ained, the yield being of 318 kg of polymer/g of Ti.
~:~ 20 The ~olymer was furthermore characterized by the following properties: .
- bulk density 0.37 kg/l - particles' average dia. 333 ~ `
- grade E 49.2 g/10' EXAMPLE 5 ~.
a) Preparation of the catalysts 13.88 g of Mg(OC2H5) 2 were mixed with 14.7 g : Cl3SiCzH~ and 6.34 g of vinyl-tris-(beta-methoxy-ethoxy)-silane.
~bm:~
378~
The mixture was gradually heated to 155C
and kept a~ such temperature for 2 hours. After cooling, a semi-solid paste was obtained, that was treated with 240 ml of TiCl4 at 136C for 2 hours. The not reacted TiCl4 was decanted and siphoned in hot conditions. The solid residue was re-treated two consecutive times with boiling TiCll,, every time for 1 hour and with analogous amounts.
By operating according to example la), a solid product was obtained, whose elemental analysis yielded the following results:
Mg = 19.6 % by weight, Ti = 2.85 % by weight, Cl = 68.i5 % by waight.
b) PoLymerization of propylene in a solvent It was operated following example lb), employing 229 mg of the solid product prepared according to example 5a), 1.135 ~ of Al(C2H5) 3 and 572 mg of ethylanisate.
By operating in this way it was possible to obtaln 135 g of polypropylene, having a residue to the extraction with boiling heptane equal to 77.5%, the yield being of 20,700 g of polymer/g of Ti in 5 hours.
c) Polymerization of propylene in a li~uid monomer It was operated following the modalities of - example lc), employing 850 mg of the solid product prepared according to example 5a), 12.5 g of Al(C2H~) 9 ' ' and 7.2 g of ethylanisate, 1.28 kg of polypropylene, having a residue to the extraction with boiling heptane bm:~
, .. , .,,, , ., . , . , . .. . , . .. . . ... , ~ .,. .. ,,, . ... .. . . . , . .. ., .. :
37~8~8 of 85~o I were thus obtained, the yeild heing of 52,800 g of polymer/g of Ti.
The polymer was furthermore characterized by the following properties: `
- bulk density 0.39 kg/l - intrinsic viscosity 1.2 dl/g - melt-flow index 7.5 g/10' - flexural rigidity 11,050 kg/cm2 a) Preparation of the catalyst 13.75 g of Mg(OC2H5)2 were mixed with 19.62 g of Cl3SiC2H5, 3.38 g of benzoyl chloride and 3.38 g of polydimethysiloxane (viscosity: 100 Cst).
The mixture was gradually heated, u~der stirring, to 155C and kept at such temperature for 2 hours.
By operating according to the modalities of example 5a), a solid product was obtained, whose elemental~analysis yielded the following results:
;~ 20 Mg = 21.6 ~ by weight, Ti = 1.25~ by weight, Cl = 68.95~ by weight.
b) Polymerization o~ propylene in a solvent It was operated as in example lb), using 234 mg of the solid product prepared according to example 6a), 1.135 g of Al(C2H3)9 and 572 mg of ethylanisate.
276 g of polypropylene in particle-form, free from powders, were thus obtained, having a residue to the extraction with boiling heptane equal to 86.5%, the yield being of 94,500 g of polymer/g of Ti in 5 hours, ~ . .
~, -23- ``
~ 788f~
The polymer was ~urthermore characterized by the following properties:
- bulk density 0.42 kg/l - intrinsic viscosity 1.9 dl/g - melt-flow index 4.7 g/10' - flexural rigidity 9,760 kg/cm2.
c) Pol~nerization of propylene in a liquid monomer It was operated following example lc), using 815 mg of the solid product prepared according to example 6a), 12.5 g of Al(C2H5) 9 and 7.2 g of ethylanisate. Thus, it was possible to obtain 2.35 kg of particle-form polypropylene free from powder, having a residue to the extraction with boiling heptane of 86%i, the yield being of 230,000 g of polymer/g of Ti.
The polymer was also characterized by the following properties: ;
- bulk density 0.47 kg/l :
- intrinsic viscosity 1.8 dl/g ;
- melt-flow index 3 g/10' - flexural rigidity 10,300 kgjcm2.
.. . . . - .. ..
a) Preparation of the catalyst Example 6a) was repeated, but using 1.68 g ;~
of benzoyl chloride and 13.73 g of polydimethylsiloxane.
A solid product was obtained, whose elemental analysis yielded the following results:
Mg = 19.4 % by weight;
Ti = 1. 55% by welght;
Cl = 65~i by weight.
88q~
b) Polymer.ization o~ propylene in a solvent It was operated as in example lb), using 221 mg of the solid product prepared according to example 7a), 1.135 g of Al(C2H~) 3 and 572 mg of ethylanisate.
Z70 g of particle-form polypropylene, free from powder, having a residue to the extraction with boiling heptane of 81.5%, were thus obtained, the yield being of 78,800 g of polymer/g of Ti in 5 hours.
The polymer exhibited also the following properties:
- bulk density 0.44 kg/l - intrinsic viscosity 1.3 dl/g - melt-flow index 13.2 g/10' - flexural rigidity 13,500 kg/cm2.
c) Polymerization of propylene in a liquid monomer It was operated following the modalities of exampLe lc), employing 740 mg of the solid product prepared according to example 7a), 12.5 g of Al(C2H,) 3 :
and 7.2 g of ehtylanisate. In this way, 1.67 kg of a particle-form polypropylene, free from powder, having .
a residue to the extraction with boiling heptane of 87.5~, were obtained, the yield being of 145,500 g of polymer/g of Ti.
The polymer was furthermore characterized by the following properties:
.
- bulk density 0.41 kg/l : - intrinsic viscosity 1.5 dl/g . ~ -melt-flow index 9 g/10' - flexural rigidity 14,700 kg/cm~.
~ -25-~~ -~m:~
~ ~788~)8 ~ ~ ., a) Preparation of the catalyst 19. 6 g Of Cl3SiC2~1s were admixed to 13.73 g of Mg(OC2H5)2. The resulting mixture was gradually heated to 145C, and kept at such temperature for 2 hours under stirring. The semi-fluid paste so obtained was repeatedly washed at 68C with n-hexane by decantation.
The solid suspended in 50 ml of n-hexane was added with l.Bl g of ethyl benzoate and 1.81 g of polydimethylsiloxane (viscosity = 100 cst.).
The mixture was heated to 70C and kept at such temperature for 1 hour. It was evaporated under a moderate vacuum at 50C, and the solid residue obtained -was treated with 240 ml of boiling TiCl4 for 2 hours.
After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid residual. After several washings in hot conditions (68C) with n-hexane, it was filtered under vacuum at 60C.
A solid product was so obtained, whose elemental analysis yielded the following results:
Mg - 17.16~ by weight, . :' Ti = 2.2 ~ by weight, - Cl = 60.65% by weight.
b) Polymerization of pro~lene in a solvent It was operated following example lb), employing 187 mg of the =olid product prepared according to example 8a), 1.135 g of Al(C2H5) 3 and 572 mg of ethylanisate. In this way it was possible to obtain 165 g of particle-form dry polypropylene, having a residue to the extraction bm:~
. - - -~ - . - ,, - - ~ : ,, ,, .; . . ... .. -: .. : . .
~07880B
, ..
with boiling heptane of 86.5~, the yield being of 40,2~0 g of pol~iner/g o~ Ti Thie polymer was furthermore characterized by the following properties:
- bulk density 0.40 kg/l - intrinsic viscosity 1.6 dl/g - melt-flow index 8.4 g/10' - flexural rigidity 11,880 kg/cm2.
c) Polymerization of propylene in a liquid monomer It was operated as in example lc), using 740 mg of the solid product prepared according to example 8a), 12.5 g of Al(C2H~) 3 and 7.2 g of ethylanisate. In this way, 1.35 kg of particle-form polypropylene, having a residue to the extraction with boiling heptaine of 87~, were obtained, the yield being of 82,800 g of polymer/g of Ti. The polymer was furthermore characterized by the following properties:
- bulk density 0.41 kg/l ~ intrinsic viscosity1.4 dl/g - melt-flow index 5.6 g/10' - flexural rigidity11,850 kg/cm2.
EXA~IPLE 9 Example 7b) was repeated but using 155 mg of the solid catalyst component prepared according to example 7a), 1,135 g of Al(C2H5) 3 and 640 mg of ethylanisate.
- In this case, the polymerization was effected in n-heptane under a pressure of 10 kg/cm2 gauge (lo 5~ by volume of hydrogen in the gas phase) for 6 hours.
`~ ~078~
In this way 260 g of polypropylene were obtained in "particle form" ~ree from powder, with a yield of 108,000 g of polymer/g of Ti, having a residue to extraction with boiling heptane o~ 85%, a bulk density of 0.45 kg/l, a melt-flow-index of 13.7 g/10' and a flexural rigidity of 12,440 kg/cm2.
~XAMPLE 10 a) Preparation of the catalyst 19.6 g of SnCl4 were admixed to 13.73 g of Mg(OC2H,) 2. The resulting mixture was gradually heated to 145C, and kept at such temperature for 2 hours under stirring. The semi-fluid paste so obtained was repeatedly washed at 68C with n-hexane by decantation.
The solid suspended in 50 ml of n-hexane was ~-added with 1.81 g of ethyl ben~oate and 1.81 g of polydimethylsiloxane ~viscosity = 100 cst.).
The mixture was heated to 70C and kept at such temperature for 1 hour. It was evaporated under a moderate vacuum at 50C, and the solid residue ohtained was treated with 240 ml of boiling TiCl4 for 2 hours. ;
After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid residual. After several washings in hot conditions (68C) with n-hexane, it was filtered under vacuum at 60C.
b) Polymerization of propylene in a solvent It was operated following example lb), employing 197 mg of the solid product prepared according to example - 10 a), 1.135 g of Al(C2H,) 3 and 572 mg of ethylanisate.
In this way it was possible to obtain 170 g of dry , :, ..
~ 37~
pol~propylene, having a residue to the extrac~ion with boiliny heptana of 85%.
The polymer was furthermore characterized by the following properties:
- bulk density 0.41 kg/l - intrinsic viscosity 1.6 dl/g :.
- melt-flow index 8.4 g/10' - flexural rigidity 11,880 kg/cm2.
c) Polymerization of propylene in a liquid monomer It was operated as in example lc), using 780 mg of the solid product prepared according to example 10 a), 12.5 g of Al(C2H5) 3 and 7.2 g of ethylanisate.
In this way, 1.40 kg of polypropylene, having a residue to the extraction with boiling heptane of 85~, were obtained.
The polymer was furthermore characterized by the following properties:
- bulk density 0,42 kg/l - intrinsic viscosity 1.4 dl/g ..
- melt-flow index 5.6 g/10' - flexural rigidity 11,850 kg/cm2.
a) Preparation of the catalyst 119 g SOCl2 were admixed to 11.45 g of Mg(OC2H~) 2 . The resulting mixture was gradually heated to 60C, and kept at such temperature for 2 hours under stirring. The excess SOCl 2 was removed and the solid product so obtained was repeatedly washed at 68~C with n-hexane by decantation.
: -29-.'' , : '' ' , ' . ' ' , :. ' ' ' ' ~V7~3808 The solid suspended in 100 ml of n-hexane was added with 3 g of e~hyl benzoate and 1.81 g o~
polydimethylsiloxane (viscosity = 100 cst.).
The mixture was heated to 70C and kept at such temperature for 1 hour. It was evaporated under a moderate vacuum at 50C, and the solid residue obtained was treated with 240 ml of boiling TiCl4 for 2 hours.
After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid residual. After several washings in hot conditions ~68C) with n-hexane, it was filtered under vacuum at '':.:
60~C.
b) Polymerization of propylene in a solvent -It was operated following example lb), employing 190 mg of the solid product prepared according to example lla), 1.135 g of Al(C2H5) 3 and 572 mg of ethylanisate.
In this way it was possible to obtain 168 g of polypropylene, having a residue to the extraction with boiling heptane of 84~.
20 ~ The polymer was furthermore characterized by the following properties:
- bulk density 0.39 kg/l - intrinsic viscosity 1.6 dl/g - melt-flow index 8.4 g/10' - flexural rigidity 11,880 kg/cm2.
c) Polymerization of ~ropylene in a liquid monomer It was operated as in example lc), using 770 mg of the solid product prepared according to example lla), 12.5 g of AI(CzH,) 3 and 7.2 g of ethylanisate. In this bm~
~378808 ..
.
way, 1.3 kg of particle-form polypropylene, having a residue to the extraction with boiling heptane of 85%
were obtained.
The polymer was furthermore characterized by the following proper~ies:
- bulk density 0.40 kg/l - intrinsic viscosity1.4 dl/g - melt-flow index 5.6 g/10' - flexural rigidity11,880 kg/cm2.
a) Preparation of the catalyst 11.45 g of Mg(OC~H5) 2 were admixed with 200 ml of n-hexane and 3 g of ethyl benzoate. In the resulting mixture kept at 0C, gaseous anhydrous HCl was bubbled for 1 hour.
The solid product so obtained was filtered and repeatedly washed at 0C with n-hexane till complete removal of HCl and then was treated with 240 ml of boiling TiCl4 for 2 hours.
~ After hot-filtration, a new treatment with boiling TiCl4 was carried out for 1 hour on the solid ~:
residual.
After several washings in hot conditions (68C) with n-hexane, it was filtered under vacuum at 60C.
b) Polymerization of propylene in a solvent Tt was operated following example lb), employing~l85 mg of the solid product prepared according to example 12a) 1.135 g of Al(C2H,) 3 and 572 mg of ethylanisate. In this way it was possible to obtain ,.
~.
bm: ~
~'78~3~8.
160 g of polypropylene, having a residue to the ex~rac~ion with boiling heptane of 86%. ~
The polymer was furthermore characterized by ~ -the following properties:
- bulk density 0.40 kg/l - intrinsic viscosity1.6 dl/g - melt-flow index 8.4 g/10' - flexural rigidity11,880 kg/cm2.
c) Polymerization of propylene in a li~uid monomer It was operated as in example lc), using 735 mg of the solid product prepared according to example 12a), 12.5 g of Al(C2H5) 3 and 7.2 g of ethylanisate. In this way, 1.3 kg of polypropylene, having a residue to the extraction with boiling heptane of 87~, were obtained.
The polymer was furthermore characterized by the following properties:
- bulk density 0.41 kg/l - intrinsic viscosity1.4 dl/g - melt-flow index 5.6 g/10' - flexural rigidity11,850 kg/cm2.
a~ Preparation of the catalyst -.
4 g of ClMgN(C4H9) 2 were reacted in an inert gas atmosphere with a solution contain mg 0.615 ml of ethyl benzoate in 20 ml of SiC14 at 65C under stirring for 24 hours.
. .
~he resulting white solid was filtered, washed with 200 ml of desulphurized anhydrous n-heptane, dried and reacted with 50 ml .
of TiCl4 at 130C for 2 hours under stirring. TiCl4 was removed by filtration and further 50 ml of same were added;
.
- bm: ~
~ 788~3 .
the whole was allowed to react for urkher 2 hours at 13~C, whereupon it was filtered and washed at 80C with 300 ml of n-heptane. The solid thus obtained revealed, on analysis, a Ti content equal to 2,17~ by weight and ~ Cl content of 68%.
b) Polymerization of propylene in a solvent 5 millimoles (1 g) of aluminium triisobutyl were reacted at room temperature with 1.25 millimoles (187 mg) of methyl para-toluate in 80 ml of anhydrous desulphurized n-heptane for 5 minutes.
50 ml of such solution were contacted with a suitable amo`unt of the catalyst component prepared as described hereinabove.
The remaining 30 ml were diluted to 1,000 ml with n-heptane and introduced, under a nitrogen pressure, into a steel atuoclave equipped with stirrer, thermoregulated at 40C, whereinto propylene was made to flow.
In the same way the catalytic component suspension was then introduced. After closing of the autoclave, hydrogen was added up to a partial pressure of 0.1 atm., and then it was heated to 60~C under contemporaneous feeding of propylene up to a totaI pressure of 5 atmospheresO Such pressure was kept constant throughout the polymerization by going on feeding the monomer. After 4 hours the polymerization was stopped and the polypropylene was isolated by treating it with methanol and acetone.
.
The results of the polymerization test are reported on Table 1.
3.3 g of MglN(C4Hg) 2] 2 were reacted in an inert gas ~^ bm:~ -~ . - - - ; ~ - -, . ~ .. . . . :
. . - . . ~ -~.~378B~)~
atmosphere with a solution containing 0.52 ml of ethyl benzoate in 30 ml of SiC1~ at 65C under stirring for 24 hours. The resulting white solid was filtered, washed with 200 ml of desulphurized anhydrous n-heptane, dried and caused to react -with 50 ml of TiC14 at 130C for two hours under stirring.
~ iCl4 was removed by filtration and further 50 ml of same were added; it was allowed to react for further two hours at 130C, then it was filtered and washed at 80C with 300 ml of n-heptane. The solid so obtained exhibited on analysis a Ti content equal to 2~ and a Cl content of 65%.
A propylene polymerization test conducted by using such compound as catalyst component, under the same conditions as described in example 13, gave the results reported on Table 1.
10.4 g of ClMgN(C6H5) 2 were reacted in an inert gas atmosphere with a solution containing 1.44 ml of ethyl benzoate in 90 ml of SiCl4 at 65C under stirring for 24 hours.
The resulting white solid was filtered, washed with 200 ml of desulphurized anhydrous n-heptane and reacted with ,.~....
100 ml of TiCl4 at 80C for two hours under stirring. ~;
TiC14 was removed by filtration and further 100 ml of same were added, it was allowed to react for further two hours at 80C, then it was filtered and washed at 80C with 300 ml of n-heptane. The solid thus obtained revealed, on analysis, a Ti content of~2.37% and a Cl content of 50.5~, The propylene polymerization test was carried out by using such compound as catalytic component, under the same conditions as described in example 13; the results obtained S
~ ~78l3~1~
.
are those reported on Table 1.
T A B L E
. _ . ..... .
-ATALYST i POLYMERIZATION -.
. , Example I YIELD (1) Heptane (2) g of polypropylene i residue g of Ti dl/g %
......
13 1 56,000 2 12 89 ..
14 56,000 1.6 85 _ .. .. _ .. _. _ .. ... ...... . .
38,000 1.6 91 .
(1) Inherent viscosity measured in tetrahydro naphthalene at 135C (polymer concentration :
0.25 g in 100 ml of solvent)~
(2) Residue to the extraction with boiling n-heptane.
aj Preparation of the catalyst 11.44 g of Mg(OEt) 2 along with 136 g of SiCl4 and 2.81 g of C6~5COCl were charged in the order into a pyrex glass 250 ml reactor, e~uipped with filtering fritted bottom, The suspension was brought, under stirring, to 60C and kept at such temperature for 21 hours, Subsequently it was filtered at 60C and evaporated to dryness.
The residual solid product was treated with 200 ml of TiCl4 at l35C for two hours. A filtration was effected at 135C, removing the unreacted TiCl~. Successively a treatment with 200 ml of TiCl4 at 135C for 1 hour was conducted. It was hot-filtered a~ain and the residual solid was washed with bm:1l 78~V8 .
hot hexane ~ - in order to remove the TiCl~ in excess.
It was dried under vacuum at 60C, thus obtaining a solid product, whose elemental analysis provided the following results: -Cl = 58.55% by weight Ti = 2.05% by weight.
b) Pol~merization of prop~lene in a solvent 119 mg of the solid product described hereinabove were introduced into a stainless steel 2.5 1 autoclave, containing 1 1 of hexane and 1.135 g of Al-triisobutyl premixed with 344 mg of dimethyl para-toluate (solution at 20 g/100 ml of C6). Polymerization was conducted at 60C, at a pressure of 9 kg/cm2 gauge, with propylene and hydrogen (1.5~ by volume of the gas phase) for 4 hours.
The pressure was kept constant by continuous feeding of propylene.
At the conclusion, after removal of the solvent by stripping with vapour, 520 g of dry polypropylene were obtained, the yield being of 213!000 g of polymer/g of Ti, and the residue to the extraction with boiling heptane being of 92.5%.
a) Preparation of the catalyst The reactor described in example 16 was fed, in the order, with : 11.50 g of Mg(OEt) 2 ~ 135 g of SiCl4 and 3 g o ethyl benzoate; this mixture was heated to 60C, under stirring, and kept at such temperature for 24 hours consecutively.
lt was filtered at 60C to dryness of the solid, whereupon it was repeatedly washed with hot hexane removing SiCl4 in excess : -36-:bm: ,5. .
~7~3~V8 The residual solid product was treated with 200 ml of TiCl4 at 135C for 2 hours. The dissolved products as well as the TiC14 in excess were removed by filtration at 135C.
A second treatment was effected by employing 200 ml of TiC14 for l hour at 135C. After removal by filtration of the whole amount of hot TiCl4, the solid residue was repeatedly washed with hot hexane, in order to remove the TiCl~, in excess.
It was dried under vacuum at 50C, thus obtaining a solid product, whose elemental analysis provided the following results: .
Ti = 1.95 % by weight Cl = 67.25~ by weight~
b) Polymerization of propylene in a solvent .
It was operated as in example 16 b), using 61.8 mg of the solid product prepared as described hereinbefore, l.135 g of Al-triisobutyl and 274 mg of methyl p-toluate (solution at 20 g/lO0 ml of C6 )-By operating in this way, 331 g of dry "particle form"polymer were obtained, the yield being of 275,000 g of polypropylene/g of Ti, and the residue to the extraction with boiling heptane being~of 90.5%.
c) Polymerization of propylene in a solvent 60 mg of the solid product prepared as described hereinbefore were introduced into a stainless steel 2.5 1 autoclave containing l l of C6+ and l g of Al-triisobutyl premixed with 254 mg of methyl p-toluate (solution at 20 g/lO0 ml of C6 ). Polymerization was conducted at 60C, at a pressure of 5.4~kg/cm2 gauge, with propylene and hydrogen (1.5~ by volume of the gas phase) for 5 hours.
bm: ~
- - . . .
~ 7~38~
.-- .
- By OperAt.ing in this way, 254 g of dry "particle-form"
polymer were obtained, the yield being of 217,000 g of poly-propylene/g of Ti, and the residue to the extraction in boiling heptane being equal to 92.5%.
a) Preparation of the catalyst A reactor like that described in example 16 a) was charged, in the order, with 11.45 g of Mg(OEt) 2 ~ 208.5 g of SnCl4 and 3 g of ethyl benzoate; this mixture was heated, under stirring to 60C for 24 hours consecutively.
Successively it was filtered at 60C up to solid dryness, whereupon it was repeatedly washed with hot hexane in order to completely remove SnCl4.
The residual solid product was treated with 200 ml of TiCl4 at 135C for 2 hours. The dissolved products and the TiCl4 in excess were removed by filtration at 135C, A
successive treatment with 200 ml of TiCl4 was then carried out for 1 hour at 135C. It was filtered again in hot conditions and the residual solid was washed with hot hexane in order to remove the TiCl4 in excess.
It was dried under vacuum at 50C, thus obtaining a solid product, whose elemental analysis provided the following results:
-Cl - 70.1~ ~ by weight Ti = 1.35 ~ by weight.
b) Polymerization of propylene in a solvent It was operated as described in example 16 b~ by using 88 mg of the solid product prepared as described hereinbefore, 1 g of Al-triisobutyl and 254 mg of methyl :':
- -bm~ f .. . . . . , . . . , . ~. , .. ... , . ~ . . . . . . . . . . ... .. .
,. : , . ~ : :. :.-., . . ~, . . :
~Y8 !3~
p-toluate (solution at 5.5 g/100 ml of C6 ) .
Ry operating in this way, 366 g of dry polymer were - `
. obtained, the yield being of 308,000 g of polypropylene/g of : -Ti, and the residue to the extraction with boiling heptane being of 87.5~.
`
. . - . . ~ -~.~378B~)~
atmosphere with a solution containing 0.52 ml of ethyl benzoate in 30 ml of SiC1~ at 65C under stirring for 24 hours. The resulting white solid was filtered, washed with 200 ml of desulphurized anhydrous n-heptane, dried and caused to react -with 50 ml of TiC14 at 130C for two hours under stirring.
~ iCl4 was removed by filtration and further 50 ml of same were added; it was allowed to react for further two hours at 130C, then it was filtered and washed at 80C with 300 ml of n-heptane. The solid so obtained exhibited on analysis a Ti content equal to 2~ and a Cl content of 65%.
A propylene polymerization test conducted by using such compound as catalyst component, under the same conditions as described in example 13, gave the results reported on Table 1.
10.4 g of ClMgN(C6H5) 2 were reacted in an inert gas atmosphere with a solution containing 1.44 ml of ethyl benzoate in 90 ml of SiCl4 at 65C under stirring for 24 hours.
The resulting white solid was filtered, washed with 200 ml of desulphurized anhydrous n-heptane and reacted with ,.~....
100 ml of TiCl4 at 80C for two hours under stirring. ~;
TiC14 was removed by filtration and further 100 ml of same were added, it was allowed to react for further two hours at 80C, then it was filtered and washed at 80C with 300 ml of n-heptane. The solid thus obtained revealed, on analysis, a Ti content of~2.37% and a Cl content of 50.5~, The propylene polymerization test was carried out by using such compound as catalytic component, under the same conditions as described in example 13; the results obtained S
~ ~78l3~1~
.
are those reported on Table 1.
T A B L E
. _ . ..... .
-ATALYST i POLYMERIZATION -.
. , Example I YIELD (1) Heptane (2) g of polypropylene i residue g of Ti dl/g %
......
13 1 56,000 2 12 89 ..
14 56,000 1.6 85 _ .. .. _ .. _. _ .. ... ...... . .
38,000 1.6 91 .
(1) Inherent viscosity measured in tetrahydro naphthalene at 135C (polymer concentration :
0.25 g in 100 ml of solvent)~
(2) Residue to the extraction with boiling n-heptane.
aj Preparation of the catalyst 11.44 g of Mg(OEt) 2 along with 136 g of SiCl4 and 2.81 g of C6~5COCl were charged in the order into a pyrex glass 250 ml reactor, e~uipped with filtering fritted bottom, The suspension was brought, under stirring, to 60C and kept at such temperature for 21 hours, Subsequently it was filtered at 60C and evaporated to dryness.
The residual solid product was treated with 200 ml of TiCl4 at l35C for two hours. A filtration was effected at 135C, removing the unreacted TiCl~. Successively a treatment with 200 ml of TiCl4 at 135C for 1 hour was conducted. It was hot-filtered a~ain and the residual solid was washed with bm:1l 78~V8 .
hot hexane ~ - in order to remove the TiCl~ in excess.
It was dried under vacuum at 60C, thus obtaining a solid product, whose elemental analysis provided the following results: -Cl = 58.55% by weight Ti = 2.05% by weight.
b) Pol~merization of prop~lene in a solvent 119 mg of the solid product described hereinabove were introduced into a stainless steel 2.5 1 autoclave, containing 1 1 of hexane and 1.135 g of Al-triisobutyl premixed with 344 mg of dimethyl para-toluate (solution at 20 g/100 ml of C6). Polymerization was conducted at 60C, at a pressure of 9 kg/cm2 gauge, with propylene and hydrogen (1.5~ by volume of the gas phase) for 4 hours.
The pressure was kept constant by continuous feeding of propylene.
At the conclusion, after removal of the solvent by stripping with vapour, 520 g of dry polypropylene were obtained, the yield being of 213!000 g of polymer/g of Ti, and the residue to the extraction with boiling heptane being of 92.5%.
a) Preparation of the catalyst The reactor described in example 16 was fed, in the order, with : 11.50 g of Mg(OEt) 2 ~ 135 g of SiCl4 and 3 g o ethyl benzoate; this mixture was heated to 60C, under stirring, and kept at such temperature for 24 hours consecutively.
lt was filtered at 60C to dryness of the solid, whereupon it was repeatedly washed with hot hexane removing SiCl4 in excess : -36-:bm: ,5. .
~7~3~V8 The residual solid product was treated with 200 ml of TiCl4 at 135C for 2 hours. The dissolved products as well as the TiC14 in excess were removed by filtration at 135C.
A second treatment was effected by employing 200 ml of TiC14 for l hour at 135C. After removal by filtration of the whole amount of hot TiCl4, the solid residue was repeatedly washed with hot hexane, in order to remove the TiCl~, in excess.
It was dried under vacuum at 50C, thus obtaining a solid product, whose elemental analysis provided the following results: .
Ti = 1.95 % by weight Cl = 67.25~ by weight~
b) Polymerization of propylene in a solvent .
It was operated as in example 16 b), using 61.8 mg of the solid product prepared as described hereinbefore, l.135 g of Al-triisobutyl and 274 mg of methyl p-toluate (solution at 20 g/lO0 ml of C6 )-By operating in this way, 331 g of dry "particle form"polymer were obtained, the yield being of 275,000 g of polypropylene/g of Ti, and the residue to the extraction with boiling heptane being~of 90.5%.
c) Polymerization of propylene in a solvent 60 mg of the solid product prepared as described hereinbefore were introduced into a stainless steel 2.5 1 autoclave containing l l of C6+ and l g of Al-triisobutyl premixed with 254 mg of methyl p-toluate (solution at 20 g/lO0 ml of C6 ). Polymerization was conducted at 60C, at a pressure of 5.4~kg/cm2 gauge, with propylene and hydrogen (1.5~ by volume of the gas phase) for 5 hours.
bm: ~
- - . . .
~ 7~38~
.-- .
- By OperAt.ing in this way, 254 g of dry "particle-form"
polymer were obtained, the yield being of 217,000 g of poly-propylene/g of Ti, and the residue to the extraction in boiling heptane being equal to 92.5%.
a) Preparation of the catalyst A reactor like that described in example 16 a) was charged, in the order, with 11.45 g of Mg(OEt) 2 ~ 208.5 g of SnCl4 and 3 g of ethyl benzoate; this mixture was heated, under stirring to 60C for 24 hours consecutively.
Successively it was filtered at 60C up to solid dryness, whereupon it was repeatedly washed with hot hexane in order to completely remove SnCl4.
The residual solid product was treated with 200 ml of TiCl4 at 135C for 2 hours. The dissolved products and the TiCl4 in excess were removed by filtration at 135C, A
successive treatment with 200 ml of TiCl4 was then carried out for 1 hour at 135C. It was filtered again in hot conditions and the residual solid was washed with hot hexane in order to remove the TiCl4 in excess.
It was dried under vacuum at 50C, thus obtaining a solid product, whose elemental analysis provided the following results:
-Cl - 70.1~ ~ by weight Ti = 1.35 ~ by weight.
b) Polymerization of propylene in a solvent It was operated as described in example 16 b~ by using 88 mg of the solid product prepared as described hereinbefore, 1 g of Al-triisobutyl and 254 mg of methyl :':
- -bm~ f .. . . . . , . . . , . ~. , .. ... , . ~ . . . . . . . . . . ... .. .
,. : , . ~ : :. :.-., . . ~, . . :
~Y8 !3~
p-toluate (solution at 5.5 g/100 ml of C6 ) .
Ry operating in this way, 366 g of dry polymer were - `
. obtained, the yield being of 308,000 g of polypropylene/g of : -Ti, and the residue to the extraction with boiling heptane being of 87.5~.
`
Claims (14)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. Solid catalyst component for polymerizing ethylene and/or alpha olefins, comprising compounds containing Ti, Mg and halogens, in which the halogen/Mg atomic ratio is not less than 1, said component being prepared by reacting a halogenated compound of tetravalent Ti with the solid halogenation product obtained by reaction of a halogenating agent different from the halogenated compound of tetravalent Ti, with a Mg compound selected from the group consisting of:
(a) organic oxygenated Mg compounds of the formula XMgOR
in which R is an alkyl, aryl, cycloalkyl or acyl radical containing from 1 to 20 carbon atoms or -OR forms an enolate radical containing from 1 to 20 carbon atoms, and X is OR, halogen, (SO4) 1/2, - OH,(CO3) 1/2, (PO4) 1/3, carboxylate or an alkyl, aryl, or cycloalkyl radical con-taining from 1 to 20 carbon atoms (b) organometallic compounds of the formula YMgR' in which R' is an alkyl t aryl, or cycloalkyl radical containing from 1 to 20 carbon atoms, and Y is halogen or R'; and (c) Mg organic compounds of the formula in which R" and R"' are hydrogen or alkyl or aryl radicals containing from 1 to 20 carbon atoms; and X is or has the same significance as in (a); said catalyst component being further characterized in that it contains an electron-donor in a quantity not greater than 1.0 mole per g-atom of Mg.
(a) organic oxygenated Mg compounds of the formula XMgOR
in which R is an alkyl, aryl, cycloalkyl or acyl radical containing from 1 to 20 carbon atoms or -OR forms an enolate radical containing from 1 to 20 carbon atoms, and X is OR, halogen, (SO4) 1/2, - OH,(CO3) 1/2, (PO4) 1/3, carboxylate or an alkyl, aryl, or cycloalkyl radical con-taining from 1 to 20 carbon atoms (b) organometallic compounds of the formula YMgR' in which R' is an alkyl t aryl, or cycloalkyl radical containing from 1 to 20 carbon atoms, and Y is halogen or R'; and (c) Mg organic compounds of the formula in which R" and R"' are hydrogen or alkyl or aryl radicals containing from 1 to 20 carbon atoms; and X is or has the same significance as in (a); said catalyst component being further characterized in that it contains an electron-donor in a quantity not greater than 1.0 mole per g-atom of Mg.
2. The solid catalyst component of claim 1 in which the electron-donor compound is bound to the halogenation product.
3. The solid catalyst component of claim 1, in which the halogenation product is reacted with a halogenated compound of tetravalent Ti.
4. The solid catalyst component according to claim 1, characterized in that the halogenating agent is selected from silicon halogenated compounds having the formula XmSiRn, in which X is a halogen, R is an alkyl, cycloalkyl and aryl radical C1-C20, n + m = 4, 1?m ?4 and 0 ?n ?3, and from amongst the halogenation products of polysiloxanes.
5. The solid catalyst component according to claim 1, characterized in that the electron-donor compound is selected from amongst the esters of inorganic and organic oxygenated acids and the polyamides.
6. The solid catalyst component according to claim 1, 2 or 3 characterized in that the electron-donor compound consists of a silicon compound selected from vinyl-tris-(beta-methoxyethoxy) silane and gamma-methacryloxy-propyl-tris-(methoxy)silane.
7. The solid catalyst component according to claim 1, 2 or 3, characterized in that said Ti compounds are selected from amongst titanium alcoholates, haloalcoholates and halides.
8. The solid catalyst component according to claim 3, characterized in that said Ti compound is TiCl4.
9. The solid catalyst component according to claim 5, characterized in that it is prepared in the presence of a silicon compound, either polymeric or not, containing the group in which R' and R" are the same or different hydrocarbon radicals of the alkyl type C1-C6 or aryl type or R' is hydrogen.
10. Catalyst for polymerizing ethylene and/or alpha-olefins containing at least three carbon atoms, or mixtures of same, comprising the product of the reaction of:
a) addition and/or substitution product of an electron-donor compound with metallorganic aluminum compound free of halogen atoms bound to the Al atoms, in which product the molar ratio between the electron-donor groups of the electron-donor com-pound which are reacted with the metallorganic Al compound and the total moles of the Al compound is comprised between 0.01 and 1, with b) the solid catalyst component of claim 1, in such quantity to have an atomic ratio Al/Ti in the catalyst between 1 and 10,000.
a) addition and/or substitution product of an electron-donor compound with metallorganic aluminum compound free of halogen atoms bound to the Al atoms, in which product the molar ratio between the electron-donor groups of the electron-donor com-pound which are reacted with the metallorganic Al compound and the total moles of the Al compound is comprised between 0.01 and 1, with b) the solid catalyst component of claim 1, in such quantity to have an atomic ratio Al/Ti in the catalyst between 1 and 10,000.
11. Catalyst for polymerizing ethylene or mixtures of olefins containing a major proportion of ethylene, comprising the product of the reaction of:
a) an aluminum alkyl compound with b) the solid catalyst compound of claim l.
a) an aluminum alkyl compound with b) the solid catalyst compound of claim l.
12. Process for polymerizing alpha-olefins, containing at least three carbon atoms, or mixtures of same or of same with smaller amounts of ethylene, characterized by contacting the monomer or monomers with a catalyst of claim 10.
13. Process for the preparation of stereoregular polymers of propylene, characterized in that propylene is contacted with a catalyst according to claim 10 and that the polymerization is carried out in the presence of hydrocarbon inert diluents, liquid under the polymerization conditions, or in liquid propylene.
14. Process for preparing polymers and copolymers of ethylene by polymerization of ethylene or of mixture of olefins containing a major proportion of ethylene, characterized in that the monomers are contacted with a catalyst according to claim 11.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IT27438/75A IT1042711B (en) | 1975-09-19 | 1975-09-19 | COMPONENTS OF CATALYSTS FOR THE POLYMERIZATION OF OLEFINS |
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| Publication Number | Publication Date |
|---|---|
| CA1078808A true CA1078808A (en) | 1980-06-03 |
Family
ID=11221640
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA259,430A Expired CA1078808A (en) | 1975-09-19 | 1976-08-19 | Catalysts and catalyst components for polymerizing olefins |
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| Country | Link |
|---|---|
| US (2) | US4115319A (en) |
| AT (1) | AT343892B (en) |
| AU (1) | AU501269B2 (en) |
| BR (1) | BR7603129A (en) |
| CA (1) | CA1078808A (en) |
| ES (1) | ES448086A1 (en) |
| FR (1) | FR2324652A1 (en) |
| GB (1) | GB1550195A (en) |
| IN (1) | IN145461B (en) |
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| ZA (1) | ZA762246B (en) |
Families Citing this family (134)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL7613855A (en) * | 1975-12-18 | 1977-06-21 | Sumitomo Chemical Co | PROCESS FOR POLYMERIZING OLEFINS. |
| JPS5948003B2 (en) * | 1976-06-02 | 1984-11-22 | 三井化学株式会社 | Method for producing polyolefins |
| IT1068112B (en) * | 1976-08-09 | 1985-03-21 | Montedison Spa | COMPONENTS OF CATALYSTS FOR THE POLYMERIZATION OF ALPHA OLEFINS AND CATALYSTS FROM THEM OBTAINED |
| JPS58448B2 (en) * | 1976-09-27 | 1983-01-06 | 三井化学株式会社 | Method for manufacturing polyolefin |
| IT1078995B (en) * | 1977-05-24 | 1985-05-08 | Montedison Spa | CATALYSTS FOR THE POLYMERIZATION OF OLEFINE |
| US4232138A (en) * | 1977-12-19 | 1980-11-04 | Standard Oil Company (Indiana) | Olefin polymerization catalyst |
| IT1092448B (en) * | 1978-02-09 | 1985-07-12 | Montedison Spa | CATALYSTS FOR THE POLYMERIZATION OF ALPHA-OLEFINS |
| US4258167A (en) * | 1978-02-13 | 1981-03-24 | Nissan Chemical Industries, Ltd. | Process for producing powdery isotactic polyolefin |
| CA1104298A (en) * | 1978-02-23 | 1981-06-30 | Akinobu Shiga | Catalysts for the polymerization of olefins |
| US4295992A (en) * | 1978-06-30 | 1981-10-20 | The Dow Chemical Company | Support prepared from organomagnesium compounds and silicon halides; and catalysts for polymerizing olefins |
| DE2831830A1 (en) * | 1978-07-20 | 1980-01-31 | Basf Ag | METHOD FOR PRODUCING A COMPONENT FOR POLYMERIZATION CATALYSTS |
| JPS5919566B2 (en) * | 1978-07-28 | 1984-05-07 | 東亜燃料工業株式会社 | Method for producing catalyst component for α-olefin polymerization |
| IT1099416B (en) * | 1978-10-23 | 1985-09-18 | Montedison Spa | COMPONENTS AND CATALYSTS FOR THE POLYMERIZATION OF OLEFINS |
| IT1099805B (en) * | 1978-10-26 | 1985-09-28 | Montedison Spa | COMPONENTS AND CATALYSTS FOR THE POLYMERIZATION OF OLEFINS |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3644318A (en) * | 1968-08-21 | 1972-02-22 | Hoechst Ag | Process for the polymerization of olefins |
| DE2043508A1 (en) * | 1970-09-02 | 1972-03-16 | Farbwerke Hoechst AG, vorm. Meister Lucius & Brüning, 6000 Frankfurt | Process for the production of polyolefins |
| US3989880A (en) * | 1971-02-18 | 1976-11-02 | Solvay & Cie | Catalyst and process for the polymerization of olefins |
| BE785673A (en) * | 1971-06-30 | 1973-01-02 | Naphtachimie Sa | POLYMERIZATION CATALYZERS OF OLEFINS PREPARED FROM DECOMPOSED ORGANOMAGNESIANS |
| US3819599A (en) * | 1972-05-31 | 1974-06-25 | Standard Oil Co | Catalyst and process for the polymerization of ethylene and terminal olefins |
-
1975
- 1975-09-19 IT IT27438/75A patent/IT1042711B/en active
-
1976
- 1976-04-14 ZA ZA762246A patent/ZA762246B/en unknown
- 1976-04-15 AU AU13069/76A patent/AU501269B2/en not_active Expired
- 1976-04-21 IN IN689/CAL/76A patent/IN145461B/en unknown
- 1976-04-28 GB GB17150/76A patent/GB1550195A/en not_active Expired
- 1976-05-17 AT AT358676A patent/AT343892B/en not_active IP Right Cessation
- 1976-05-18 BR BR7603129A patent/BR7603129A/en unknown
- 1976-05-20 ES ES448086A patent/ES448086A1/en not_active Expired
- 1976-05-26 FR FR7616022A patent/FR2324652A1/en active Granted
- 1976-08-19 CA CA259,430A patent/CA1078808A/en not_active Expired
- 1976-09-17 US US05/724,361 patent/US4115319A/en not_active Expired - Lifetime
-
1980
- 1980-09-16 US US06/187,734 patent/USRE31099E/en not_active Expired - Lifetime
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| Publication number | Publication date |
|---|---|
| BR7603129A (en) | 1977-11-22 |
| FR2324652B1 (en) | 1980-04-18 |
| FR2324652A1 (en) | 1977-04-15 |
| ZA762246B (en) | 1977-04-27 |
| GB1550195A (en) | 1979-08-08 |
| ES448086A1 (en) | 1977-07-01 |
| ATA358676A (en) | 1977-10-15 |
| USRE31099E (en) | 1982-12-07 |
| IN145461B (en) | 1978-10-14 |
| AT343892B (en) | 1978-06-26 |
| AU501269B2 (en) | 1979-06-14 |
| AU1306976A (en) | 1977-10-20 |
| IT1042711B (en) | 1980-01-30 |
| US4115319A (en) | 1978-09-19 |
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