Fina Technology, Inc.

W. R. Grace Co.-conn.

Braskem America, Inc.

Total Petrochemicals Research Feluy

Vladimir P Marin

Abbas Razavi

Margarito Lopez

Ahmed Hintolay

Michael Spencer

Binh Thanh Nguyen

Neil J O'Reilly

Jonas Alves Fernandes

Mushtaq Ahmed Patel

Main Chang

Tim J Coffy

Jan Willem Van Egmond

Michel Daumerie

Kayo Umezawa-Vizzini

Didier Baekelmans

Razavi Abbas

Neil J O'reilly

A process of preparing a solid catalyst component for the production of polypropylene includes a) dissolving a halide-containing magnesium compound in a mixture, the mixture including an epoxy compound, an organic phosphorus compound, and a hydrocarbon solvent to form a homogenous solution; b) treating the homogenous solution with an organosilicon compound during or after the dissolving step; c) treating the homogenous solution with a first titanium compound in the presence of a first non-phthalate electron donor, and an organosilicon compound, to form a solid precipitate; and d) treating the solid precipitate with a second titanium compound in the presence of a second non-phthalate electron donor to form the solid catalyst component, where the process is free of carboxylic acids and anhydrides.

Process for preparing solid catalyst components for olefin polymerization

An activated solid catalyst component is disclosed formed from a magnesium compound, a titanium compound, an organosilicon compound, a supportive electron donor, and at least one internal electron donor. The solid catalyst component is activated to include titanium and carbon bonds by reaction with an activation agent, such as an aluminum compound. In one embodiment, small amounts of polymer are polymerized with the catalyst component during activation. The activated catalyst component is stable and, when formed, can later be used to produce various polyolefin polymers. The activated catalyst component has controlled reaction kinetics so that the catalyst does not overheat and degrade during initial polymerization.

Activated catalyst components for olefin polymerization

Catalyst components for propylene polymerization

The present disclosure is generally directed to polyolefin polymers, such as polypropylene homopolymers, and propylene-ethylene copolymers that have improved flow properties. In one embodiment, the polymers can be produced using a solid catalyst component that includes a) dissolving a halide-containing magnesium compound in a mixture, the mixture including an epoxy compound, an organic phosphorus compound, and a hydrocarbon solvent to form a homogenous solution; b) treating the homogenous solution with an organosilicon compound during or after the dissolving step; c) treating the homogenous solution with a first titanium compound in the presence of a first non-phthalate electron donor, and an organosilicon compound, to form a solid precipitate; and d) treating the solid precipitate with a second titanium compound in the presence of a second non-phthalate electron donor to form the solid catalyst component, where the process is free of carboxylic acids and anhydrides.

Polyolefin polymer composition

A solid catalyst component for use in olefinic polymerization, includes titanium, magnesium, a halogen, and an internal electron donor compound; wherein: the internal electron donor compound is at least one compound represented by Formula (I)): 

Non-phthalate donor for polyolefin catalysts

A process for preparing a solid pre-catalyst component for use in olefinic polymerization includes dissolving a magnesium chloride in an alcohol and optionally adding water to form a first solution having a water content of about 0.5 mmol water per mol MgClto about 100 mmol water per mol MgCl; contacting the first solution with a first titanium compound to form the solid pre-catalyst component; and treating the solid pre-catalyst component with a hydrocarbon or halogenated hydrocarbon solvent, optionally containing a second titanium compound.

Olefin polymerization catalyst

A solid catalyst component for use in olefinic polymerization, includes titanium, magnesium, a halogen, and an internal electron donor compound; wherein: the internal electron donor compound is at least one compound represented by Formula (I)). 

Solid catalyst components for use in olefin polymerization, olefin polymerization catalyst systems containing the solid catalyst components, methods of making the solid catalyst components and the catalyst systems, and methods of polymerizing and copolymerizing olefins involving the use of the catalyst systems. The solid catalyst components are formed by (a) dissolving a magnesium compound and an auxiliary intermediate electron donor in at least one first solvent to form a solution; (b) contacting a first titanium compound with said solution to form a precipitate of the magnesium compound and the first titanium compound; (c) washing the precipitate with a mixture of a second titanium compound and at least one second solvent and optionally an electron donor at a temperature of up to 90&#xb0; C.; and (d) treating the precipitate with a mixture of a third titanium compound and at least one third solvent at 90-150&#xb0; C. to form a solid catalyst component.

Process of polymerization catalyst production with controlled catalyst properties and use of same in olefin polymerizations

Solid catalyst components are disclosed including titanium, magnesium, halogen and an internal electron donor compound having a combination of internal electron donor compounds including at least one 1,8-naphthyl diester and at least one secondary internal donor compound selected from alkyl 2-alkoxy-1-naphthoates, alkyl 2-alkoxybenzoates, alkyl 2,6-dialkoxybenzoates, (2-alkoxyphenyl)(pyrrolidin-1-yl)alkanones, dialkyl phthalates, alkyl alkionates, and dialkyl cyclohexane-1,2-dicarboxylates, and catalyst systems containing the catalyst solid components, organoaluminum compounds, and organosilicon compounds. Further, methods of making the catalyst components and the catalyst systems are disclosed as well as methods of polymerizing or copolymerizing alpha-olefins using the catalyst systems.

Combined internal donor system for Ziegler-Natta polyolefin catalysts and methods of making and using same

A method of making a solid catalyst component for production of a polyolefin, including the steps of: a) dissolving a halide-containing magnesium compound in a mixture including alkylepoxide, an organic phosphorous compound, a carboxylic acid or anhydride, and a hydrocarbon solvent to form a homogenous solution; b) optionally treating the homogeneous solution with a halogenating agent; c) treating the homogenous solution with a first titanium halide compound in the presence of a surface modifier and optionally a first electron donor to form a solid precipitate, wherein, if present, the first electron donor is an ether; d) optionally treating the solid precipitate with a second electron donor; and e) treating the solid precipitate with a second titanium halide compound and optionally with a second electron donor to form the solid catalyst component.

Process for preparing spherical polymerization catalyst components for use in olefin polymerizations

Solid catalyst components for use in olefin polymerization, systems incorporating the same, methods of producing the same, and methods of use are disclosed. The solid catalyst components are formed by (a) dissolving a magnesium compound and an auxiliary intermediate electron donor in at least one first solvent to form a solution; (b) contacting a first titanium compound with said solution to form a precipitate of the magnesium compound and the first titanium compound; (c) washing the precipitate with a mixture of a second titanium compound and at least one second solvent and optionally an electron donor at a temperature of up to 90&#xb0; C.; and (d) treating the precipitate with a mixture of a third titanium compound and at least one third solvent at 90-150&#xb0; C. to form a solid catalyst component.

Methods of forming supported catalyst systems, supported catalyst systems and polymerization processes utilizing the supported catalyst systems are described herein. The methods generally include providing an inorganic support material and contacting the inorganic support material with a support solvent to form a support solution. The methods further include contacting the support solution with a fluorine containing compound represented by the formula AlFXBto impregnate the fluorine containing compound within the inorganic support material and form an intermediate, wherein X is selected from Cl, Br and OH, B is HO, p is selected from 1 to 3 and q is selected from 0 to 6. In addition, the methods include drying the intermediate to remove the solvent therefrom and heating the intermediate at a temperature of at least about 300&#xb0; C. to form an impregnated support and contacting the impregnated support with a transition metal compound to form a supported catalyst system, wherein the transition metal compound is represented by the formula [L]M[A]; wherein L is a bulky ligand, A is a leaving group, M is a transition metal and m and n are such that a total ligand valency corresponds to the transition metal valency.

Fluorinated impregnated catalyst systems and methods of forming the same

Supported catalyst systems and methods of forming the same are described herein. In one specific embodiment, the methods generally include providing an inorganic support material and contacting the inorganic support material with an aluminum fluoride compound represented by the formula AlFXBto form an aluminum fluoride impregnated support, wherein X is selected from Cl, Br and OH, B is HO, p is selected from 1 to 3 and q is selected from 0 to 6. The method further includes contacting the aluminum fluoride impregnated support with a transition metal compound to form a supported catalyst system, wherein the transition metal compound is represented by the formula [L]M[A]; wherein L is a bulky ligand, A is a leaving group, M is a transition metal and m and n are such that a total ligand valency corresponds to the transition metal valency.

Fluorinated transition metal catalysts and formation thereof

Catalyst compositions and processes for the polymerization of ethylenically unsaturated monomers to produce polymers, including copolymers or homopolymers. Such monomers include ethylene, Calpha olefins and substituted vinyl compounds, such as styrene and vinyl chloride. The polymerization catalyst characterized by the formula B(FluL)MQin which Flu is a fluorenyl group substituted at at least the 2,7- and 3,6-positions by hydrocarbyl groups, preferably relatively bulky hydrocarbyl groups. L is a substituted or unsubstituted cyclopentadienyl, indenyl or fluorenyl group or a heteroorgano group, XR, in which X is a heteroatom from Group 15 or 16 of the Periodic Table of Elements, such as nitrogen, R is an alkyl group, a cycloalkyl group or an aryl group and B is a structural bridge extending between the groups L and Flu, which imparts stereorigidity to the ligand structure, M is a Group 4 or Group 5 transition metal, such as titanium, zirconium or hafnium and Q is selected from the group consisting of chlorine, bromine, iodine, an alkyl group, an amino group, an aromatic group and mixtures thereof, with n being 1 or 2.

Preparation and use of tetrasubstituted fluorenyl catalysts for polymerization of olefins

In accordance with the present invention, there is provided a transition metal olefin polymerization catalyst component characterized by the formula: where, M is a Group IV or a Group IV transition metal, B is a bridge group containing at least two carbon atoms, A' and A&#x2033; are organogroups, each containing a heteroatom selected from the group consisting of oxygen, sulfur, nitrogen and phosphorus, X is selected from the group consisting of chlorine, bromine, iodine, a C-Calkyl group, a C-Caromatic group and mixtures thereof, and n is 1, 2 or 3. The invention also encompasses a method for the polymerization of an ethylenically unsaturated monomer which comprises contacting a transition metal catalyst component as characterized by formula (1) above and an activating co-catalyst component in a polymerization reaction zone with an ethylenically unsaturated monomer under polymerization conditions to produce a polymer product.

Growing community of inventors

Houston, TX, United States of America

Vladimir P Marin