Catalyst Component For Olefin Polymerization, Preparation Method Thereof, And Catalyst Comprising Same

Catalyst Component For Olefin Polymerization, Preparation Method Thereof, And Catalyst Comprising Same (China Petroleum & Chemical Corporation)
United States Patent Application 20160264694
Xia; Xianzhi ;   et al.   September 15, 2016
Applicant: China Petroleum & Chemical Corporation
Applicant: Beijing Research Institute Of Chemical Industry, China Petroleum & Chemical Corporation
Abstract
The present invention provides a catalyst component for olefin polymerization and a preparation method thereof, and a catalyst for olefin polymerization and an application thereof. The catalyst component for olefin polymerization comprises reaction products of the following components: (1) a solid component; (2) at least one titanium compound; and (3) at least two internal electron donors, wherein the solid component comprises a magnesium compound represented by formula (1) and an epoxide represented by formula (2), wherein R.sub.1 is a C.sub.1-C.sub.12 linear or branched alkyl; R.sub.2 and R.sub.3 are identical or different, and are independently hydrogen or unsubstituted or halogen-substituted C.sub.1-C.sub.5 linear or branched alkyl; X is halogen; m is in a range of from 0.1 to 1.9, n is in a range of from 0.1 to 1.9, and m+n=2. ##STR00001##
FIELD OF THE INVENTION
[0002] The present invention relates to a catalyst component for olefin polymerization, a method for preparing a catalyst component, a catalyst component for olefin polymerization prepared by the method, a catalyst for olefin polymerization comprising the catalyst component, and use of the catalyst for olefin polymerization in olefin polymerization.
BACKGROUND ART
[0003] Most of catalysts for olefin polymerization are prepared by supporting a titanium halide on an active magnesium chloride. A common method used to prepare the active magnesium chlorides is to react anhydrous MgCl.sub.2 with an alcohol to form a magnesium chloride-alcohol adduct of general formula: MgCl.sub.2.mROH.nH.sub.2O. Then, a titanium halide is supported on such an adduct to afford a solid catalyst component for olefin polymerization. Such alcohol adducts may be prepared by known processes, such as spray drying process, spray cooling process, high-pressure extruding process, or high-speed stirring process. See, for example, U.S. Pat. No. 4,421,674, U.S. Pat. No. 4,469,648, WO8707620, WO9311166, U.S. Pat. No. 5,100,849, U.S. Pat. No. 6,020,279, U.S. Pat. No. 4,399,054, EP0395383, U.S. Pat. No. 6,127,304 and U.S. Pat. No. 6,323,152.
[0004] Other magnesium-containing complex carriers useful in the preparation of catalysts for olefin polymerization are also known in the art. For example, CN102040681A discloses a compound that can be used as a carrier of catalysts for olefin polymerization, having a structure of:
##STR00002##
wherein R.sub.1 is a C.sub.1-C.sub.12 linear or branched alkyl; R.sub.2 and R.sub.3 are identical or different, and are independently hydrogen or unsubstituted or halogen-substituted C.sub.1-C.sub.5 linear or branched alkyl; X's are chlorine or bromine, and one of the X's may be C.sub.1-C.sub.14 alkyl, C.sub.1-C.sub.14 alkoxy, C.sub.6-C.sub.14 aryl or C.sub.6-C.sub.14 aroxy; m is in a range of from 0.1 to 1.9, n is in a range of from 0.1 to 1.9, and p+m+n=2. Said compound is prepared as follows: MgX.sub.2 reacts with an alcohol of general formula R.sub.IOH in the presence of an inert dispersion medium at 30 to 160.degree. C., to form a magnesium halide-alcohol adduct solution; then the solution reacts with an oxirane compound at 30 to 160.degree. C., to form the magnesium compound useful as a carrier, wherein X is chlorine or bromine, R.sub.1 is a C.sub.1-C.sub.12 linear or branched alkyl. CN102040680A also discloses an olefin polymerization catalyst, which is prepared by using said compound useful as a carrier of olefin polymerization catalyst disclosed in the above-mentioned patent application.
[0005] There is still need a catalyst component for olefin polymerization that exhibits desired properties, such as high activity and high stereo-directing ability, and a method by which such a catalyst component can be simply, effectively, and low-costly prepared.
SUMMARY OF THE INVENTION
[0006] An object of the invention is to provide a novel catalyst component for olefin polymerization.
[0007] A further object of the invention is to provide a method for preparing the catalyst component for olefin polymerization.
[0008] A still further object of the invention is to provide a catalyst for olefin polymerization comprising the catalyst component.
[0009] A still further object of the invention is to provide use of the catalyst in olefin polymerization.
[0010] In some embodiments, the present invention provides a catalyst component for olefin polymerization, comprising reaction products of the following components:
[0011] (1) a solid component;
[0012] (2) at least one titanium compound; and
[0013] (3) at least two internal electron donors;
[0014] wherein the solid component comprises a magnesium compound represented by formula (1) and an epoxide represented by formula (2),
##STR00003##
wherein, R.sub.I is a C.sub.1-C.sub.12 linear or branched alkyl; R.sub.II and R.sub.III are identical or different, and are independently hydrogen or unsubstituted or halogen-substituted C.sub.1-C.sub.5 linear or branched alkyl; X is halogen; m is in a range of from 0.1 to 1.9, n is in a range of from 0.1 to 1.9, and m+n=2; and
[0015] wherein the content of the epoxide represented by the formula (2) is in a range of from 0.01 to 0.8 moles per mole of the magnesium compound represented by the formula (1).
[0016] In some embodiments, the present invention provides a method for preparing the catalyst component, which method comprises the steps of:
[0017] (1) preparing a solid component by a process comprising:
[0018] (a) reacting a magnesium halide of formula MgX.sub.2 with an alcohol of formula R.sub.IOH in the presence of at least one polymeric dispersion stabilizer at 30 to 160.degree. C. in a closed vessel, to form a magnesium halide-alcohol adduct solution; and
[0019] (b) reacting the magnesium halide-alcohol adduct solution with an epoxide represented by formula (2):
##STR00004##
at 30 to 160.degree. C., to form a solid component,
[0020] wherein, X is halogen; R.sub.I is a C.sub.1-C.sub.12 linear or branched alkyl; R.sub.II and R.sub.III are identical or different, and are independently hydrogen or unsubstituted or halogen-substituted C.sub.1-C.sub.5 linear or branched alkyl, and
[0021] wherein, relative to one mole of the magnesium halide, the amount of the alcohol used ranges from 3 to 30 moles and the amount of the epoxide represented by the formula (2) used ranges from 1 to 10 moles, and the polymeric dispersion stabilizer is used in an amount of from 0.1 to 10 wt %, based on the total weight of the magnesium halide and the alcohol; and
[0022] (2) contacting and reacting the solid component from step (1) with a titanium compound in the presence or absence of an inert solvent, and adding at least two internal electron donors at one or more stages before, during and/or after the reaction.
[0023] In some embodiments, the present invention provides a catalyst component for olefin polymerization prepared by the above-described method.
[0024] In some embodiments, the present invention provides a catalyst for olefin polymerization, comprising:
[0025] (i) the catalyst component for olefin polymerization according to the present invention;
[0026] (ii) at least one alkyl aluminum compound; and
[0027] (iii) optionally, at least one external electron donor.
[0028] In some embodiments, the present invention provides use of the catalyst for olefin polymerization in olefin polymerization reaction.
[0029] By means of these technical solutions, the present invention achieves the following virtues:
[0030] (1) in the preparation of the solid component, solid particles having good particle morphology and narrow particle size distribution can be obtained without adding an inert dispersion medium, thereby enhancing the solid component output of unit volume of reactor;
[0031] (2) compared to the inert dispersion media used in the prior art, the polymeric dispersion stabilizer used in the preparation of the solid component can be recovered more easily, thereby reducing the costs associated with the recovering;
[0032] (3) when the catalysts for olefin polymerization according to the invention are used in olefin polymerization (especially propylene polymerization or copolymerization), the resultant polymers have relatively high isotacticities; and
[0033] (4) the catalysts for olefin polymerization according to the invention exhibit high activities.
[0034] These and other features and virtues of the invention will be apparent from the following description in details.
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