Borealis Ag

Alexander Reznichenko

Ville Virkkunen

Noureddine Ajellal

Luigi Maria Cristoforo Resconi

Joseph Thorman

Victor Sumerin

Jari-Jussi Ruskeeniemi

Xiao Dong Chen

Alexander Z Voskoboynikov

Timo Leinonen

Peter Denifl

Vyatcheslav V Izmer

Dmitry S Kononovich

Kalle Kallio

Pascal Castro

Dietrich Gloger

Marja Mustonen

Simon Schwarzenberger

Irfan Saeed

Wilfried Toeltsch

Frank Schröder

Werner Verwimp

Bernard Binks

Luigi Resconi

Soile Lustig

Hans Kerkhofs

Kristof Wehenkel

Improved preparation process for supported catalyst systems, which comprise a specific class of metallocene complexes in combination with a boron containing cocatalyst and an aluminoxane cocatalyst and use of the new, improved catalyst system.

Preparation of catalyst system

A specific class of metallocene complexes in combination with a boron containing cocatalyst and an aluminoxane cocatalyst, its use for producing propylene homopolymers, propylene copolymers, especially with ethylene, as well as heterophasic propylene copolymers, preferably in a multistep process including a gas phase polymerization step.

Catalyst system

A metallocene complex of formula (I): each X is a sigma-ligand; in the group RSi— at least one R is methyl or ethyl, and the other R is selected from methyl, ethyl, n-propyl, isopropyl, n-butyl or isobutyl, pentyl, hexyl, cyclohexyl and phenyl; each Rindependently is the same or can be different and are a CH—Rgroup, with Rbeing H or linear or branched C-alkyl group, Ccycloalkyl group, or Caryl group; each Ris independently a —CH═, —CY═, —CH—, —CHY— or —CY— group, wherein Y is a Chydrocarbyl group and where n is 2-6; each Rand Rare independently the same or can be different and are hydrogen, a linear or branched C-alkyl group, a Carylalkyl, Calkylaryl group, Caryl group, or an —OY group, wherein Y is a is a Chydrocarbyl group; Ris a linear or branched C-alkyl group, Carylalkyl, Calkylaryl group or C-aryl group; and Ris a C(R)group, with Rbeing a linear or branched Calkyl group; (A) wherein at least one Rper phenyl group and at least one Ris not hydrogen, and wherein at least one Rper phenyl group and at least one Ris hydrogen; or (B) wherein one Ris an —OY group, wherein Y is a is a Chydrocarbyl group, in 4 position of each phenyl group and the two other Rgroups are tert-butyl groups; and/or (C) wherein one Ris an —OY group, wherein Y is a is a Chydrocarbyl group, in 4-position of the phenyl ring and the two other Rgroups are tert-butyl groups.

Catalysts

Improved preparation process for silica supported catalyst systems, which comprise a specific class of metallocene complexes in combination with a boron containing cocatalyst and an aluminoxane cocatalyst and use of the new, improved catalyst system.

The present invention relates to a process for producing of solid particulate olefin polymerisation catalyst or catalyst carrier comprising forming a solution of the catalyst or a catalyst carrier in a solvent, subjecting the solution into an atomization by spraying the solution via a capillary vibrating spray nozzle with a capillary orifice having a diameter of 5 to 100 μm generating a laminar jet of liquid, which disintegrates into liquid droplets entering into the spray-dryer, transforming the droplets with aid of a gas to solid particulate catalyst or carrier in the spray-dryer and recovering the solid particulate olefin polymerisation catalyst or carrier having particle size distribution defined by a volumetric SPAN of 0.7 or less. The invention further relates to the catalyst produced by the methods, and use thereof in olefin polymerisation process.

Catalyst and preparation thereof

The present invention relates to a process for producing solid Ziegler-Natta catalyst component in the form of solid particles having a median particle size (D50) of 5 to 500 &#x3bc;m the process comprising steps I. providing a solution of a mixture of Group 2 metal compounds of i) a solution of a Group 2 metal dihalide and ii) at least one Group 2 metal alkoxide of the Periodic Table (IUPAC, Nomenclature of Inorganic Chemistry, 2005) II. contacting the solution of the mixture of Group 2 metal compounds of step I with a compound in a liquid form of a transition metal of Group 4 to 10, or of a lanthanide or actinide, preferably a transition metal of Group 4 to 6 of Periodic Table (IUPAC, Nomenclature of Inorganic Chemistry, 2005), and III. recovering the solid catalyst component, wherein the solution of a Group 2 metal dihalide i) is obtained by dissolving a solid Group 2 metal dihalide in an alcohol comprising at least a monohydric alcohol of formula ROH, where R is selected from hydrocarbyl of 3 to 16 C atoms, and wherein the amount of Group 2 metal originating from Group 2 metal dihalide in the solution of the mixture of Group 2 metal compounds is in the range of 5 to 90 mol-%. The invention further relates to a catalyst comprising the catalyst component and use thereof in olefin polymerisation process.

The present invention relates to a process for producing of solid particulate olefin polymerisation catalyst or catalyst carrier comprising forming a solution of the catalyst or a catalyst carrier in a solvent, subjecting the solution into an atomization by spraying the solution via a capillary vibrating spray nozzle with a capillary orifice having a diameter of 5 to 100 &#x3bc;m generating a laminar jet of liquid, which disintegrates into liquid droplets entering into the spray-dryer, transforming the droplets with aid of a gas to solid particulate catalyst or carrier in the spray-dryer and recovering the solid particulate olefin polymerisation catalyst or carrier having particle size distribution defined by a volumetric SPAN of 0.7 or less. The invention further relates to the catalyst produced by the methods, and use thereof in olefin polymerisation process.

A process for the preparation of a solid olefin polymerization catalyst or a solid olefin polymerization catalyst component comprising the steps of: (a) forming a liquid/liquid emulsion of (i) a first organic liquid comprising at least one olefin polymerization catalyst component and (ii) an optionally halogenated hydrocarbon liquid immiscible therewith; where the first organic liquid forms the dispersed phase and the optionally halogenated hydrocarbon liquid forms the continuous phase of the liquid/liquid emulsion and wherein the dispersed phase forms droplets in the continuous phase; and (b) transforming the droplets of the dispersed phase to solid particulate particles comprising said at least one olefin polymerization catalyst component, wherein the liquid/liquid emulsion is stabilized with a solid particulate stabilizer.

Process for the preparation of solid catalyst

Process for the preparation of a solid catalyst system comprising the steps of preparing a liquid clathrate comprising a mixing of an aluminoxane, an aromatic compound and an organo-silicon compound, wherein the mol-ratio between the organo-silicon compound and aluminum of the aluminoxane is below 0.1, mixing said liquid clathrate with an organometallic compound obtaining a liquid mixture, and precipitating the solid catalyst system out of said liquid mixture by adding a saturated aliphatic compound to said mixture liquid.

Growing community of inventors

Porvoo, Finland

Alexander Reznichenko