Process for the preparation of polyalk-1-enes in the presence of a supported metallocene catalyst system and an antistaticum
6 claims: 5 independent, 1 dependent
- 1Verfahren zur Herstellung von Polymerisaten von C 2 - bis C 12 -Alk-1-enen,wobei als Alk-1-ene 50 bis 100 mol-% Propen, 0 bis 50 mol-% Ethylen und 0 bis 20 mol-% C 4 - bis C 12 -Alk-1-enen eingesetzt werden, bei Temperaturen im Bereich von 0 bis 150°C und Drücken von 1 bis 80 bar in Gegenwart eines Katalysatorsystems, dadurch gekennzeichnet, daß man als Katalysatorsystem ein solches verwendet, das A) einen anorganischen oder organischen Träger, B) einen Metallocenkomplex der allgemeinen Formel IVc, in der die Substituenten folgende Bedeutung haben:M Titan, Zirkonium, Hafnium, Vanadium, Niob oder Tantal X Fluor, Chlor, Brom, Iod, Wasserstoff, C 1 - bis C 10 -Alkyl, C 6 - bis C 15 -Aryl, Alkylaryl mit 1 bis 10 C-Atomen im Alkylrest und 6 bis 20 C-Atomen im Arylrest, -OR 10 oder -NR 10 R 11 , wobei R 10 und R 11 C 1 - bis C 10 -Alkyl, C 6 - bis C 15 -Aryl, Alkylaryl, Arylalkyl, Fluoralkyl oder Fluoraryl mit jeweils 1 bis 10 C-Atomen im Alkylrest und 6 bis 20 C-Atomen im Arylrest bedeuten, R 5 bis R 7 , R 9 , R 13 bis R 15 und R 17 Wasserstoff, C 1 - bis C 10 -Alkyl, 5- bis 7-gliedriges Cycloalkyl, das seinerseits ein C 1 - bis C 10 -Alkyl als Substituent tragen kann, C 6 - bis C 15 -Aryl oder Arylalkyl, wobei gegebenenfalls auch zwei benachbarte Reste gemeinsam für 4 bis 15 C-Atome aufweisende gesättigte oder ungesättigte cyclische Gruppen stehen können, oder Si(R 12 ) 3 mit R 12 C 1 - bis C 10 -Alkyl, C 3 - bis C 10 -cycloalkyl oder C 6 - bis C 15 -Aryl bedeuten, R 19 = BR 20 , = AlR 20 , -Ge-, -Sn-, -O-, -S-, = SO, = SO 2 , = NR 20 , = CO, = PR 20 oder = P(O)R 20 ist, wobei R 20 , R 21 und R 22 gleich oder verschieden sind und ein Wasserstoffatom, ein Halogenatom, eine C 1 -C 10 -Alkylgruppe, eine C 1 -C 10 -Fluoralkylgruppe, eine C 6 -C 10 -Fluorarylgruppe, eine C 6 -C 10 -Arylgruppe, eine C 1 -C 10 -Alkoxygruppe, eine C 2 -C 10 -Alkenylgruppe, eine C 7 -C 40 -Arylalkylgruppe, eine C 8 -C 40 -Arylalkenylgruppe oder eine C 7 -C 40 -Alkylarylgruppe bedeuten oder wobei zwei benachbarte Reste jeweils mit den sie verbindenden Atomen einen Ring bilden, und M 2 Silicium, Germanium oder Zinn ist, C) eine metalloceniumionenbildende Verbindung und D) gegebenenfalls eine Metallverbindung der allgemeinen Formel I M 1 (R 1 ) r (R 2 ) s (R 3 ) t I in der M 1 ein Alkali-, ein Erdalkalimetall oder ein Metall der III. Hauptgruppe des Periodensystems bedeutet, R 1 Wasserstoff, C 1 - bis C 10 -Alkyl, C 6 - bis C 15 -Aryl, Alkylaryl oder Arylalkyl mit jeweils 1 bis 10 C-Atomen im Alkylrest und 6 bis 20 C-Atomen im Arylrest, R 2 und R 3 Wasserstoff, Halogen, C 1 - bis C 10 -Alkyl, C 6 - bis C 15 -Aryl, Alkylaryl, Arylalkyl oder Alkoxy mit jeweils 1 bis 10 C-Atomen im Alkylrest und 6 bis 20 C-Atomen im Arylrest, r eine ganze Zahl von 1 bis 3 und s und t ganze Zahlen von 0 bis 2 bedeuten, wobei die Summe r+s+t der Wertigkeit von M 1 entspricht, enthält, und daß man bei der Polymerisation ein Antistatikum zugibt.
- 2Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß als Alk-1-ene 50 bis 100 mol-% Propen, 0 bis 30 mol-% Ethylen und 0 bis 20 mol-% C 4 - bis C 12 -Alk-1-ene eingesetzt werden.
- 3Verfahren nach Ansprüchen 1 bis 2, dadurch gekennzeichnet, daß die Polymerisation in flüssigen Monomeren oder in der Gasphase erfolgt.
- 4Verfahren nach den Ansprüchen 1 bis 3, dadurch gekennzeichnet, daß die Polymerisation in der gerührten Gasphase erfolgt.
- 5Verfahren nach den Ansprüchen 1 bis 4, dadurch gekennzeichnet, daß zunächst, in Anwesenheit des Antistatikums, eine Vorpolymerisation in Suspension oder flüssigem Monomeren erfolgt.
- 6Verfahren nach den Ansprüchen 1 bis 5, dadurch gekennzeichnet, daß als metalloceniumionenbildende Verbindung C) offenkettige oder cyclische Alumoxanverbindungen der allgemeinen Formel II oder III wobei R 4 eine C 1 - bis C 4 -Alkylgruppe bedeutet und m für eine ganze Zahl von 5 bis 30 steht, eingesetzt werden.
Independent claims6
109 paragraphs, as filed
The present invention relates to processes for the preparation of polymers of C.<sub>2</sub>- to C<sub>12</sub>-Alk-1-enes, where as Alk-1-enes<ul id="ul0001" list-style="none"><li>50 up to 100 mol% propene,</li><li>0 up to 50 mol% ethylene and</li><li>0 up to 20 mol% C<sub>4</sub>- to C<sub>12</sub>-Alk-1-ene</li></ul> be used at temperatures in the range from 0 to 150 ° C and pressures in the range from 1 to 80 bar in the presence of a catalyst system.
The polymers available here are used for the production of fibers, films and moldings and the fibers, films and moldings obtainable therefrom.
Metallocene catalysts allow the production of new types of polyolefins. Support is usually required for commercial use of such metallocene catalysts in conventional industrial processes, since this gives polymers with improved morphology, as described in EP-A 294 942. However, the previous supported metallocene catalysts show a stronger tendency to form polymerization agglomerations or deposits than modern Ziegler-Natta supported catalysts. Added to this is the still very low productivity of the supported metallocene catalysts.
The use of antistatic agents as a scale-reducing additive in ethylene polymerization is described when using Ziegler or Phillips catalysts, for example in EP-A 636 636. However, by using Ziegler or Phillips catalysts, polymers with, for example, a broad molecular weight distribution are obtained . The addition of antistatic agents to Ziegler or Phillips catalysts does not improve the productivity of the catalyst.
WO 94/26793 describes a process for the preparation of supported catalyst systems, in which a water-containing support material is reacted with an organometallic compound at a substantially constant temperature, and the polymerization of ethylene using a catalyst system prepared in this way in the presence of an antistatic.
EP-A 535 230 discloses processes for the production of rubber-like ethylene copolymers in which the polymerization can take place in the presence of an antistatic.
It was therefore an object of the present invention to provide processes for the preparation of polymers of C.<sub>2</sub>- to C<sub>12</sub>-Alk-1-enes available in which polymers with a narrow molecular weight distribution are formed, which can be carried out on an industrial scale and in which there is no formation of deposits and agglomerates. In addition, the productivity of the catalyst systems used should be improved.
Accordingly, processes for the preparation of polymers of C<sub>2</sub>- to C<sub>12</sub>-Alk-1-enes, where as Alk-1-enes<ul id="ul0002" list-style="none"><li>50 up to 100 mol% propene,</li><li>0 up to 50 mol% ethylene and</li><li>0 up to 20 mol% C<sub>4</sub>- to C<sub>12</sub>-Alk-1-ene</li></ul> be used at temperatures in the range from 0 to 150 ° C. and pressures from 1 to 80 bar in the presence of a catalyst system, the catalyst system used being one which<ul id="ul0003" list-style="none"><li>A) an inorganic or organic carrier,</li><li>B) a metallocene complex of the general formula IVc,<chemistry id="chem0001" num="0001"><img file="EP0803514B1_D0001.tif" /></chemistry> and in which the substituents have the following meaning:<dl id="dl0001"><dt>M</dt><dd>Titanium, zirconium, hafnium, vanadium, niobium or tantalum</dd><dt>X</dt><dd>Fluorine, chlorine, bromine, iodine, hydrogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl with 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical, -OR<sup>10</sup> or -NR<sup>10</sup>R<sup>11</sup>,</dd></dl> in which<dl id="dl0002"><dt>R<sup>10</sup> and R<sup>11</sup></dt><dd>C.<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl, arylalkyl, fluoroalkyl or fluoroaryl each having 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical,</dd><dt>R<sup>5</sup> to R<sup>7</sup>, R<sup>9</sup>, R<sup>13</sup> to R<sup>15</sup> and R<sup>17</sup></dt><dd>Hydrogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, 5- to 7-membered cycloalkyl, which in turn is a C<sub>1</sub>- to C<sub>10</sub>-Alkyl can carry as a substituent, C<sub>6</sub>- to C<sub>15</sub>Aryl or arylalkyl, where optionally also two adjacent radicals together can represent saturated or unsaturated cyclic groups having 4 to 15 carbon atoms, or Si (R<sup>12</sup>)<sub>3</sub> With</dd><dt>R<sup>12</sup></dt><dd>C.<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>3</sub>- to C<sub>10</sub>Cycloalkyl or C<sub>6</sub>- to C<sub>15</sub>Aryl mean</dd><dt>R<sup>19</sup></dt><dd><chemistry id="chem0002" num="0002"><img file="EP0803514B1_D0002.tif" /></chemistry><chemistry id="chem0003" num="0003"><img file="EP0803514B1_D0003.tif" /></chemistry> = BR<sup>20</sup>, = AlR<sup>20</sup>, -Ge-, -Sn-, -O-, -S-, = SO, = SO<sub>2</sub>, = NO<sup>20</sup>, = CO, = PR<sup>20</sup> or = P (O) R<sup>20</sup> is in which</dd><dt>R<sup>20</sup>, R<sup>21</sup> and R<sup>22</sup></dt><dd>are identical or different and represent a hydrogen atom, a halogen atom, a C<sub>1</sub>-C<sub>10</sub>Alkyl group, a C<sub>1</sub>-C<sub>10</sub>-Fluoroalkyl group, a C<sub>6</sub>-C<sub>10</sub>-Fluoroarylgruppe, a C<sub>6</sub>-C<sub>10</sub>Aryl group, a C<sub>1</sub>-C<sub>10</sub>Alkoxy group, a C<sub>2</sub>-C<sub>10</sub>Alkenyl group, a C<sub>7</sub>-C<sub>40</sub>Arylalkyl group, a C<sub>8</sub>-C<sub>40</sub>Arylalkenyl group or a C<sub>7</sub>-C<sub>40</sub>-Alkylarylgruppe mean or where two adjacent radicals each form a ring with the atoms connecting them, and</dd><dt>M<sup>2</sup></dt><dd>Is silicon, germanium or tin,</dd></dl></li><li>C) a compound forming metallocenium ions and</li><li>D) optionally a metal compound of the general formula I M<sup>1</sup> (R<sup>1</sup>)<sub>r</sub> (R<sup>2</sup>)<sub>s</sub> (R<sup>3</sup>)<sub>t</sub> I. in the<dl id="dl0003"><dt>M<sup>1</sup></dt><dd>an alkali, an alkaline earth metal or a metal of III. Main group of the periodic table means</dd><dt>R<sup>1</sup></dt><dd>Hydrogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl or arylalkyl, each having 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical,</dd><dt>R<sup>2</sup> and R<sup>3</sup></dt><dd>Hydrogen, halogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl, arylalkyl or alkoxy, each having 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical,</dd><dt>r</dt><dd>an integer from 1 to 3</dd></dl> and<dl id="dl0004"><dt>s and t</dt><dd>are integers from 0 to 2, the sum r + s + t of the valency of M<sup>1</sup> corresponds to</dd></dl> contains,</li></ul> and that an antistatic is added during the polymerization.
In addition, the use of the polymers obtainable here for the production of fibers, films and moldings was found, as was the fibers, films and moldings obtainable therefrom.
Of the C. Used in the inventive method<sub>2</sub>- to C<sub>12</sub>-Alk-1-enes are ethylene, propene, but-1-ene, pent-1-ene, 4-methyl-pent-1-ene, hex-1-ene, hept-1-ene or oct-1-ene , as well as mixtures of these C<sub>2</sub>- to C<sub>12</sub>-Alk-1-enes preferred. Homopolymers or copolymers of propene are produced, the proportion of propene in the copolymers being at least 50 mol%. In the copolymers of propene, preference is given to those which contain ethylene or 1-butene or mixtures thereof as further monomers.
Preferably used as alk-1-enes<ul id="ul0004" list-style="none"><li>50 up to 100 mol% propene</li><li>0 up to 30 mol% of ethylene and</li><li>0 up to 20 mol%, in particular 0 to 10 mol%. C.<sub>4</sub>- to C<sub>12</sub>-Alk-1-ene</li></ul> used.
If copolymers of propene are produced with ethylene, the amount of ethylene is preferably 0.5 to 50 mol%.
The sum of the mol% always results in 100.
The process according to the invention is carried out at temperatures in the range from 0 to 150 ° C. and at pressures in the range from 1 to 80 bar.
The polymerization can be carried out in solution, in suspension, in liquid monomers or in the gas phase. The polymerization is preferably carried out in liquid monomers or in the gas phase, the stirred gas phase being preferred.
The process can be carried out either continuously or batchwise. Suitable reactors include continuously operated stirred tanks, it also being possible, if appropriate, to use a number of several stirred tanks connected in series (reactor cascade).
The catalyst system used in the process according to the invention contains, as component A), an inorganic or organic support. The carrier materials used are preferably finely divided carriers which preferably have a particle diameter in the range from 1 to 300 μm, in particular from 30 to 70 μm. Suitable inorganic carriers are, for example, magnesium chloride or silica gels, preferably those of the formula SiO<sub>2</sub><sup>.</sup> a Al<sub>2</sub>O<sub>3</sub>, where a is a number in the range from 0 to 2, preferably 0 to 0.5; So these are aluminosilicates or silicon dioxide. Such products are commercially available, for example Silica Gel 332 from Grace. For example, fine-particle polyolefins are suitable as organic carriers, for example fine-particle polypropylene.
The amount of carrier is preferably 50 to 99.9% by weight, based on the metallocene complex (component B).
As component B) the catalyst system used in the process according to the invention contains one or more metallocene complexes of the general formula IVc<chemistry id="chem0004" num="0004"><img file="EP0803514B1_D0004.tif" /></chemistry> in which the substituents have the following meaning:<dl id="dl0005"><dt>M</dt><dd>Titanium, zirconium, hafnium, vanadium, niobium or tantalum</dd><dt>X</dt><dd>Fluorine, chlorine, bromine, iodine, hydrogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl with 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical, -OR<sup>10</sup> or -NR<sup>10</sup>R<sup>11</sup>,</dd></dl> in which<dl id="dl0006"><dt>R<sup>10</sup> and R<sup>11</sup></dt><dd>C.<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl, arylalkyl, fluoroalkyl or fluoroaryl each having 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical,</dd><dt>R<sup>5</sup> to R<sup>7</sup>, R<sup>9</sup>, R<sup>13</sup> to R<sup>15</sup> and R<sup>17</sup></dt><dd>Hydrogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, 5- to 7-membered cycloalkyl, which in turn is a C<sub>1</sub>- to C<sub>10</sub>-Alkyl can carry as a substituent, C<sub>6</sub>- to C<sub>15</sub>Aryl or arylalkyl, where optionally also two adjacent radicals together can represent saturated or unsaturated cyclic groups having 4 to 15 carbon atoms, or Si (R<sup>12</sup>)<sub>3</sub> With</dd><dt>R<sup>12</sup></dt><dd>C.<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>3</sub>- to C<sub>10</sub>Cycloalkyl or C<sub>6</sub>- to C<sub>15</sub>Aryl mean</dd><dt>R<sup>19</sup></dt><dd><chemistry id="chem0005" num="0005"><img file="EP0803514B1_D0005.tif" /></chemistry><chemistry id="chem0006" num="0006"><img file="EP0803514B1_D0006.tif" /></chemistry></dd></dl> = BR<sup>20</sup>, = AlR<sup>20</sup>, -Ge-, -Sn-, -O-, -S-, = SO, = SO<sub>2</sub>, = NO<sup>20</sup>, = CO, = PR<sup>20</sup> or = P (O) R<sup>20</sup> is in which<dl id="dl0007"><dt>R<sup>20</sup>, R<sup>21</sup> and R<sup>22</sup></dt><dd>are identical or different and represent a hydrogen atom, a halogen atom, a C<sub>1</sub>-C<sub>10</sub>Alkyl group, a C<sub>1</sub>-C<sub>10</sub>-Fluoroalkyl group, a C<sub>6</sub>-C<sub>10</sub>-Fluoroarylgruppe, a C<sub>6</sub>-C<sub>10</sub>Aryl group, a C<sub>1</sub>-C<sub>10</sub>Alkoxy group, a C<sub>2</sub>-C<sub>10</sub>Alkenyl group, a C<sub>7</sub>-C<sub>40</sub>Arylalkyl group, a C<sub>8</sub>-C<sub>40</sub>Arylalkenyl group or a C<sub>7</sub>-C<sub>40</sub>-Alkylarylgruppe mean or where two adjacent radicals each form a ring with the atoms connecting them, and</dd><dt>M<sup>2</sup></dt><dd>Is silicon, germanium or tin.</dd></dl>
The radicals X can be the same or different, they are preferably the same.
Of the compounds of the formula IVc, those in which<dl id="dl0008"><dt>R<sup>5</sup> and R<sup>13</sup></dt><dd>are the same and for hydrogen or C<sub>1</sub>- to C<sub>10</sub>Alkyl groups are available,</dd><dt>R<sup>9</sup> and R<sup>17</sup></dt><dd>are the same and represent hydrogen, a methyl, ethyl, iso-propyl or tert-butyl group</dd><dt>R<sup>6</sup>, R<sup>7</sup>, R<sup>14</sup> and R<sup>15</sup></dt><dd>the meaning R<sup>7</sup> and R<sup>15</sup> C.<sub>1</sub>- to C<sub>4</sub>-Alkyl R<sup>6</sup> and R<sup>14</sup> hydrogen have or two adjacent residues R<sup>6</sup> and R<sup>7</sup> as well as R<sup>14</sup> and R<sup>15</sup> together represent cyclic groups having 4 to 12 carbon atoms,</dd><dt>R<sup>19</sup></dt><dd>For<chemistry id="chem0007" num="0007"><img file="EP0803514B1_D0007.tif" /></chemistry> stands,</dd><dt>M</dt><dd>for titanium, zirconium or hafnium and</dd><dt>X</dt><dd>for chlorine, C<sub>1</sub>-to C<sub>4</sub>-Alkyl or phenyl are available.</dd></dl>
Examples of particularly suitable complex compounds include<ul id="ul0005" list-style="none" compact="compact"><li>Dimethylsilanediylbis (cyclopentadienyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (indenyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (tetrahydroindenyl) zirconium dichloride,</li><li>Ethylene bis (cyclopentadienyl) zirconium dichloride,</li><li>Ethylene bis (indenyl) zirconium dichloride,</li><li>Ethylene bis (tetrahydroindenyl) zirconium dichloride,</li><li>Tetramethylethylene-9-fluorenylcyclopentadienylzirconium dichloride,</li><li>Dimethylsilanediylbis (-3-tert.butyl-5-methylcyclopentadienyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-3-tert.butyl-5-ethylcyclopentadienyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-2-methylindenyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-2-isopropylindenyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-2-tert.butylindenyl) zirconium dichloride,</li><li>Diethylsilanediylbis (-2-methylindenyl) zirconium dibromide,</li><li>Dimethylsilanediylbis (-3-methyl-5-methylcyclopentadienyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-3-ethyl-5-isopropylcyclopentadienyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-2-methylindenyl) zirconium dichloride,</li><li>Dimethylsilanediylbis (-2-methylbenzindenyl) zirconium dichloride</li><li>Dimethylsilanediylbis (2-ethylbenzindenyl) zirconium dichloride,</li><li>Methylphenylsilanediylbis (2-ethylbenzindenyl) zirconium dichloride,</li><li>Methylphenylsilanediylbis (2-methylbenzindenyl) zirconium dichloride,</li><li>Diphenylsilanediylbis (2-methylbenzindenyl) zirconium dichloride,</li><li>Diphenylsilanediylbis (2-ethylbenzindenyl) zirconium dichloride, and</li><li>Dimethylsilanediylbis (-2-methylindenyl) hafnium dichloride</li></ul> as well as the corresponding dimethyl zirconium compounds.
Such complex compounds can be synthesized by methods known per se, the reaction of the appropriately substituted cyclic hydrocarbon anions with halides of titanium, zirconium, hafnium, vanadium, niobium or tantalum being preferred.
Examples of corresponding production processes are described, inter alia, in the Journal of Organometallic Chemistry, 369 (1989), 359-370.
Mixtures of different metallocene complexes can also be used.
As component C), the catalyst system used in the process according to the invention contains a compound which forms metallocenium ions.
Suitable compounds forming metallocenium ions are strong, neutral Lewis acids, ionic compounds with Lewis acid cations and ionic compounds with Bronsted acids as the cation.
Compounds of the general formula V are strong, neutral Lewis acids M<sup>3</sup>X<sup>1</sup>X<sup>2</sup>X<sup>3</sup> V preferred in the<dl id="dl0009"><dt>M<sup>3</sup></dt><dd>an element of III. Main group of the periodic table means, in particular B, Al or Ga, preferably B,</dd><dt>X<sup>1</sup>, X<sup>2</sup> and X<sup>3</sup></dt><dd>for hydrogen, C1 to C10 alkyl, C6 to C15 aryl, alkylaryl, arylalkyl, haloalkyl or haloaryl, each with 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical or fluorine, chlorine, bromine or Iodine, especially for haloaryls, preferably for pentafluorophenyl.</dd></dl>
Compounds of the general formula V in which X<sup>1</sup>, X<sup>2</sup> and X<sup>3</sup> are the same, preferably tris (pentafluorophenyl) borane.
Compounds of the general formula VI are ionic compounds with Lewis acid cations [(Y<sup>a +</sup>) Q<sub>1</sub>Q<sub>2</sub>... Q<sub>e.g.</sub>]<sup>d +</sup> VI suitable in which<dl id="dl0010"><dt>Y</dt><dd>an element of I. to VI. Main group or the I. to VIII. Subgroup of the periodic table means</dd><dt>Q<sub>1</sub> to Q<sub>e.g.</sub></dt><dd>for simply negatively charged residues like C<sub>1</sub>- to C<sub>28</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl, arylalkyl, haloalkyl, haloaryl each having 6 to 20 C atoms in the aryl and 1 to 28 C atoms in the alkyl radical, C<sub>1</sub>- to C<sub>10</sub>-Cycloalkyl, which is optionally with C<sub>1</sub>- to C<sub>10</sub>-Alkyl groups can be substituted, halogen, C<sub>1</sub>- to C<sub>28</sub>-Alkoxy, C<sub>6</sub>- to C<sub>15</sub>Aryloxy, silyl or mercaptyl groups</dd><dt>a</dt><dd>stands for integers from 1 to 6</dd><dt>e.g.</dt><dd>for integers from 0 to 5</dd><dt>d</dt><dd>corresponds to the difference az, but d is greater than or equal to 1.</dd></dl>
Carbonium cations, oxonium cations and sulfonium cations as well as cationic transition metal complexes are particularly suitable. The triphenylmethyl cation, the silver cation and the 1,1'-dimethylferrocenyl cation should be mentioned in particular. They preferably have non-coordinating counterions, in particular boron compounds, as they are also mentioned in WO 91/09882, preferably tetrakis (pentafluorophenyl) borate.
Ionic compounds with Bronsted acids as cations and preferably also non-coordinating counterions are mentioned in WO 91/09882, the preferred cation is N, N-dimethylanilinium.
The amount of compounds forming metallocenium ions is preferably 0.1 to 10 equivalents, based on the metallocene complex IV.
Open-chain or cyclic alumoxane compounds of the general formula II or III are particularly suitable as compound C) forming metallocenium ions<chemistry id="chem0008" num="0008"><img file="EP0803514B1_D0008.tif" /></chemistry><chemistry id="chem0009" num="0009"><img file="EP0803514B1_D0009.tif" /></chemistry> in which<dl id="dl0011"><dt>R<sup>4</sup></dt><dd>a C<sub>1</sub>- to C<sub>4</sub>-Alkylgruppe means, preferably methyl or ethyl group and m represents an integer from 5 to 30, preferably 10 to 25.</dd></dl>
These oligomeric alumoxane compounds are usually prepared by reacting a solution of trialkylaluminum with water and are described, inter alia, in EP-A 284 708 and US Pat. No. 4,794,096.
As a rule, the oligomeric alumoxane compounds obtained are mixtures of different lengths, both linear and cyclic chain molecules, so that m is to be regarded as the mean. The alumoxane compounds can also be present in a mixture with other metal alkyls, preferably with aluminum alkyls.
Both the metallocene complexes (component B) and the metallocenium ion-forming compounds (component C) are preferably used in solution, with aromatic hydrocarbons having 6 to 20 carbon atoms, in particular xylenes and toluene, being particularly preferred.
Furthermore, as component C) aryloxyalumoxanes, as described in US Pat. No. 5,391,793, aminoaluminoxanes, as described in US Pat. No. 5,371,260, aminoaluminoxane hydrochlorides, as described in EP-A 633,264, siloxyaluminoxanes, as in EP-A 621 279 described, or mixtures thereof are used.
It has proven advantageous to use the metallocene complexes and the oligomeric alumoxane compound in amounts such that the atomic ratio between aluminum from the oligomeric alumoxane compound and the transition metal from the metallocene complexes is in the range from 10: 1 to 10<sup>6</sup>: 1, especially in the range of 10: 1 to 10<sup>4</sup>: 1, lies.
The catalyst system used in the process according to the invention can optionally also contain a metal compound of the general formula I as component D) M<sup>1</sup> (R<sup>1</sup>)<sub>r</sub> (R<sup>2</sup>)<sub>s</sub> (R<sup>3</sup>)<sub>t</sub> I. in the<dl id="dl0012"><dt>M<sup>1</sup></dt><dd>an alkali, an alkaline earth metal or a metal of III. Main group of the periodic table, ie boron, aluminum, gallium, indium or thallium,</dd><dt>R<sup>1</sup></dt><dd>Hydrogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl or arylalkyl each having 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical,</dd><dt>R<sup>2</sup> and R<sup>3</sup></dt><dd>Hydrogen, halogen, C<sub>1</sub>- to C<sub>10</sub>-Alkyl, C<sub>6</sub>- to C<sub>15</sub>Aryl, alkylaryl, arylalkyl or alkoxy, each having 1 to 10 carbon atoms in the alkyl radical and 6 to 20 carbon atoms in the aryl radical,</dd><dt>r</dt><dd>an integer from 1 to 3</dd></dl> and<dl id="dl0013"><dt>s and t</dt><dd>are integers from 0 to 2, the sum r + s + t of the valency of M<sup>1</sup> corresponds to</dd></dl> contain.
Of the metal compounds of the general formula I, those are preferred in which<dl id="dl0014"><dt>M<sup>1</sup></dt><dd>Lithium, magnesium or aluminum means and</dd><dt>R<sup>1</sup> to R<sup>3</sup></dt><dd>for C<sub>1</sub>- to C<sub>10</sub>-Alkyl stand.</dd></dl>
Particularly preferred metal compounds of the formula I are n-butyl lithium, n-butyl-n-octyl magnesium, n-butyl-n-heptyl magnesium, tri-n-hexyl aluminum, tri-iso-butyl aluminum, triethyl aluminum and trimethyl aluminum.
If component D) is used, it is preferably in an amount of 800: 1 to 1: 1, in particular 500: 1 to 50: 1 (molar ratio of M<sup>1</sup> from I to transition metal M from IV) contained in the catalyst system.
Furthermore, an antistatic is used in the method according to the invention. In general, all antistatic agents that are suitable for polymerizations can be used. For example, salt mixtures of calcium salts of medialanic acid and chromium salts of N-stearylanthranilic acid may be mentioned , as described in DE-A 3543360. Suitable antistatic agents are also C<sub>12</sub>- to C<sub>22</sub>-Fatty acid soaps of alkali or alkaline earth metals, salts of sulfonic acid esters with the general formula (RR ') - CHOSO<sub>3</sub>Me, esters of polyethylene glycols with fatty acids, and polyoxyethylene alkyl ethers. An overview of antistatic agents is also given in EP-A 107 127.
A mixture of a metal salt of medialanic acid, a metal salt of anthranilic acid and a polyamine can also be used as an antistatic, as described in EP-A 636 636.
Commercially available products such as Stadis® 450 from Du Pont, a mixture of toluene, isopropanol, dodecylbenzenesulfonic acid, a polyamine, a copolymer of dec-1-ene and SO<sub>2</sub> and Dec-1en or ASA-3 from Shell can also be used.
The antistatic is preferably used as a solution, in the particularly preferred case of Stadis® 450 preferably 1 to 50% by weight of this solution, preferably 5 to 25% by weight, based on the mass of the supported catalyst used (support, metallocene complex and metallocenium ion-forming Connection). However, depending on the type of antistatic used, the required amounts of antistatic can vary widely.
The process according to the invention can now be carried out by first carrying out, in the presence of the antistatic, a prepolymerization in suspension, alkanes, preferably heptane or isododecane, being suitable as suspending agents, or in liquid monomers.
The preferred procedure is to suspend the support, preferably an inorganic support, in a suspending agent, preferably toluene, at a temperature in the range from 0 to 80 ° C. with a solution of the compound forming metallocenium ions over a period of 5 to 240 minutes , then stirred for 0.5 to 48 hours at temperatures in the range from 0 to 80 ° C., filtered off, washed and dried. For this purpose, a solution of the metallocene complex in a methylalumoxane solution is then preferably added and mixed at temperatures in the range from 0 to 80 ° C. over a period of 5 to 360 minutes. The solvent is then removed and the supported catalyst formed is dried.
The actual polymerization is then preferably carried out in liquid monomers (bulk) or in the gas phase, preferably in the stirred gas phase. These methods are known per se.
The preferred procedure is to add the metal compound D), preferably in a solvent such as heptane, to add the liquid alk-1-ene and to add the supported catalyst with stirring at temperatures in the range from 0 to 100.degree. The polymerization time can range from 0.01 to 24 hours, preferably 0.1 to 5 hours. If copolymers are to be prepared, the further monomer or monomers are preferably added during the actual polymerization, preferably continuously.
The process according to the invention is distinguished by the fact that it can be carried out on an industrial scale, no deposits occur, no agglomerates are formed, the productivity of the catalyst systems used has been increased, the polymers prepared by the process according to the invention are notable for a narrow molecular weight distribution and good morphology. Furthermore, polymers with a lower melting point could be obtained.
Examples
Example A: Preparation of the supported metallocene catalyst
<ul id="ul0006" list-style="none"><li>a) Silica gel loaded with methylalumoxane (MAO) 1000 g of silica gel (SG 332, pore diameter 50 µm, Grace; heated for 8 h at 180 ° C in a vacuum (1 mbar)) was dissolved in 5 l of toluene under N<sub>2</sub>- suspended atmosphere. At a temperature of 18 ° C., 7.75 l (6.38 kg) of 1.53 molar methylaluminoxane solution (in toluene, from Witco) were added over 120 minutes. The mixture was then stirred at RT (room temperature) for 7 h, filtered and the filter cake washed twice with 2.5 l of toluene. It was then dried in vacuo.</li><li>b) loading with metallocene complex 1 kg of the silica gel containing MAO prepared under a) was placed in an evacuated vessel. A solution of 5.8 g (10 mmol) of rac.-dimethylsilylenebis (2-methylbenzindenyl) zirconium dichloride in 1.32 l of 1.53 molar MAO solution (in toluene, from Witco) was then added with stirring. After pressure equalization with N<sub>2</sub> was mixed for 30 minutes at RT (room temperature). The main amount of solvent was then distilled off in vacuo (initially at 20 ° C. until no more solvent passed over). The temperature was then increased in 5 ° C. steps to 55 ° C. and the catalyst was dried until it remained as an orange, free-flowing powder.</li></ul>
Example 1:
Comparative example:
PP homopolymerization without antistatic (bulk)
In a dry, N<sub>2</sub> Flushed 1 liter autoclave was charged with 2.5 mmol of triisobutylaluminum (TIBA; 1.25 ml of a 2 molar solution in heptane). After the addition of 500 ml of liquid propene, 189 mg of supported catalyst were passed through a lock with N<sub>2</sub> shot and the autoclave heated to 60 ° C. After a reaction time of 60 minutes, the polymerization was terminated by draining off the remaining propene and the product was discharged via a bottom valve. 190 g of polymer powder were obtained, which contains approx. 2% coarse particles> 5 mm in diameter. The autoclave was then opened. There was a light polymer coating on the wall and stirrer. Productivity: 1005 g PP (polypropylene) / g supported catalyst.
Example 2:
PP homopolymerization with antistatic (bulk)
Example 1 was repeated with 192 mg of supported catalyst with the difference that before the liquid propene was added, 10 mg of a commercial antistatic solution (Stadis® 450 Du Pont) were added to the aluminum alkyl presented. 216 g of polymer powder without coarse fractions were obtained (productivity: 1125 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Information about Stadis® 450:<ul id="ul0007" list-style="none" compact="compact"><li>50 up to 65 wt% toluene</li><li>1 up to 5% by weight of isopropanol</li><li>1 up to 10% by weight of dodecylbenzenesulfonic acid</li><li>polymeric reaction product of N-alkyl-1,3-diaminopropane and epichlorohydrin (molar ratio 1: 1.5)</li><li>alternating copolymer of dec-1-ene and SO<sub>2</sub></li><li>Dec-1-en</li></ul>
Example 3:
PP homopolymerization with antistatic (bulk)
Example 2 was repeated with 200 mg of supported catalyst and 20 mg of Stadis solution. 258 g of polymer powder without coarse fractions were obtained (productivity: 1290 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 4:
PP homopolymerization with antistatic (gas phase)
Example 3 was repeated with 194 mg of supported catalyst with the difference that only 150 ml of liquid propene were initially charged, so that polymerization was carried out in the gas phase after heating. The pressure was kept constant at 24 bar. 194 g of polymer powder without coarse fractions were obtained (productivity: 1000 g PP / g supported catalyst). Autoclave wall and stirrer were free of deposits:
Example 5:
Comparative example:
PP homopolymerization without antistatic (bulk)
Example 1 was repeated with 1005 mg of supported catalyst in a 10 l autoclave (20 mmol of TIBA; 3000 g of liquid propene), but polymerization was carried out for 90 minutes. 1050 g of polymer powder with a coarse fraction of 5% by weight were obtained (productivity: 1044 g PP (polypropylene) / g supported catalyst). The autoclave wall and the stirrer showed polymer deposits and fusions.
Example 6:
PP homopolymerization with antistatic (bulk)
Example 5 was repeated with 1024 mg supported catalyst and 100 mg antistatic solution. 2030 g of polymer powder without coarse fraction were obtained (melting point T<sub>m</sub>: 142.1 ° C, number average M<sub>n</sub> : 119,000 g / mol, weight average M<sub>w</sub> : 242,000; Productivity: 1982 g PP / g supported catalyst). The autoclave wall and the stirrer were free of deposits.
The number average M<sub>n</sub> and weight averages M<sub>w</sub> were determined by means of gel permeation chromatography.
Example 7:
PP homopolymerization with antistatic (bulk)
Example 5 was repeated with 1080 mg supported catalyst, 150 mg antistatic solution and 30 mmol TIBA. 1690 g of polymer powder without coarse fraction were obtained (T.<sub>m</sub> : 141.0 ° C, M<sub>n</sub> : 127,000 g / mol, M.<sub>w</sub> : 263,000; Productivity: 1594 g PP / g supported catalyst). The autoclave wall and the stirrer were free of deposits.
Example 8:
Comparative example:
PP homopolymerization without antistatic (gas phase)
Example 5 was repeated with 1030 mg of supported catalyst, but only 1500 g of liquid propene were initially charged. When heating, the polymerization went into the gas phase and the pressure was kept constant at 24 bar. The polymerization had to be stopped after 30 minutes since the stirrer was partially blocked by chunks. 290 g of polymer powder and an additional 50 g of melted product were obtained (productivity: 330 g PP / g supported catalyst). The autoclave wall and stirrer showed heavy deposits and fusions.
Example 9:
PP homopolymerization with antistatic (gas phase)
Example 6 was repeated with 1083 mg of supported catalyst, 30 mmol of TIBA and 150 mg of antistatic solution, although only 1500 g of liquid propene were initially charged. When heating, the polymerization went into the gas phase and the pressure was kept constant at 24 bar. 1430 g of polymer powder without coarse fractions were obtained (productivity: 1320 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 10:
Ethene / propene copolymerization with antistatic (bulk)
Example 7 was repeated with 1036 mg of supported metallocene catalyst, 3500 g of liquid propene being introduced and ethene being fed in continuously during the polymerization in such a way that a total of 35 g of ethene were added at the end of the polymerization. 2070 g of polymer powder without coarse fractions were obtained<sub>m</sub> : 137.7 ° C, M.<sub>n</sub> : 133,000 g / mol, M.<sub>w</sub> : 262,000; Productivity: 1920 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 11:
Ethene / propene copolymerization with antistatic (bulk)
Example 7 was repeated with 1020 mg of supported metallocene catalyst, 3500 g of liquid propene being introduced and ethene being fed continuously during the polymerization such that a total of 70 g of ethene had been added at the end of the polymerization. 2020 g of polymer powder without coarse fractions were obtained (T<sub>m</sub> : 133.9 ° C, M.<sub>n</sub> : 102,000 g / mol; M<sub>w</sub> : 210,000; Productivity: 1980 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 12:
Ethene / propene copolymerization with antistatic (bulk)
Example 7 was repeated with 1033 mg of supported metallocene catalyst, 3500 g of liquid propene being introduced and ethene being fed continuously during the polymerization in such a way that a total of 105 g of ethene had been added at the end of the polymerization. 2280 g of polymer powder without coarse fractions were obtained (T.<sub>m</sub> : 131.5 ° C, M.<sub>n</sub> : 96,000 g / mol, M.<sub>w</sub> : 197,000; Productivity: 2207 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 13:
Ethene / propene copolymerization with antistatic (bulk)
Example 7 was repeated with 994 mg of supported metallocene catalyst, 3500 g of liquid propene being introduced and ethene being fed continuously during the polymerization such that a total of 140 g of ethene had been added at the end of the polymerization. 2230 g of polymer powder without coarse fractions were obtained (T.<sub>m</sub> : 128.9 ° C, M.<sub>n</sub> : 118,000 g / mol, M.<sub>w</sub> : 209,000; Productivity: 2243 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 14:
Ethene / propene copolymerization with antistatic (bulk)
Example 7 was repeated with 973 mg of supported metallocene catalyst, 3500 g of liquid propene being introduced and ethene being fed continuously during the polymerization in such a way that a total of 175 g of ethene had been added at the end of the polymerization. 2180 g of polymer powder without coarse fractions were obtained (T.<sub>m</sub> : 122.9 ° C, M.<sub>n</sub> : 123,000 g / mol, M<sub>w</sub> : 192,000; Productivity: 2240 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 15:
Ethene / propene copolymerization with antistatic (gas phase)
Example 13 was repeated with 1016 mg of supported metallocene catalyst, but only 1500 g of liquid propene were initially introduced, so that the polymerization was continued in the gas phase after heating. 2023 g of polymer powder without coarse fractions were obtained<sub>m</sub> : 127.1 ° C; Productivity: 1991 g PP / g supported catalyst). The autoclave wall and stirrer were free of deposits.
Example 16
Comparative example:
Ethene / propene copolymerization without antistatic (bulk)
Example 10 was repeated with 1041 mg of supported metallocene catalyst, but without an antistatic. After 45 minutes of polymerization, the polymerization had to be stopped because the stirrer was blocked by lumps and fusions (at this point, 18 g of ethene had been metered in). 532 g of polymer grit and about 200 g of strongly fused polymer chunks (diameter 1-7 cm) were obtained. Another product was fused to the stirrer blade and the autoclave wall.
24 sheets
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Every citation, both ways
| Document | Relation | Office |
|---|---|---|
| EP0535230A | Cites | European Patent Office (EPO) |
| EP0679661A | Cites | European Patent Office (EPO) |
| EP0745607A | Cites | European Patent Office (EPO) |
| WO9426793A | Cites | World Intellectual Property Organization (WIPO) |
| WO9632420A | Cites | World Intellectual Property Organization (WIPO) |
| US5459217A | Cites | United States of America |
9 members in 6 offices
Priority claims4
| Document | Office | Kind | Date |
|---|---|---|---|
| 19615953 | Germany | A | |
| 19615953 | Germany | – | |
| 19615953 | – | – | – |
| DE1996115953 | – | – | – |
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| EP0803514A1 | European Patent Office (EPO) | A1 | |
| KR970070023A | Republic of Korea | A | |
| JPH1060032A | Japan | A | |
| EP0803514B1This record | European Patent Office (EPO) | B1 | |
| DE59700778D1 | Germany | D1 | |
| US6022935A | United States of America | A | |
| ES2140931T3 | Spain | T3 | |
| KR100470842B1 | Republic of Korea | B1 |
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Numbers
- Publication
- 0803514
- Publication, DOCDB
- 0803514
- Publication, EPODOC
- EP0803514
- Application
- 97106319
- Application, DOCDB
- 97106319
- Application, EPODOC
- EP19970106319
Titles3
- German
- Verfahren zur Herstellung von Polyalk-1-enen in Gegenwart eines geträgerten Metallocenkatalysatorsystems und eines Antistatikums
- English
- Process for the preparation of polyalk-1-enes in the presence of a supported metallocene catalyst system and an antistaticum
- French
- Procédé de préparation de polymères alc-1-ènes en présence d'un système catalytique à base de métallocène supporté et d'un agent antistatique
Classification
- CPC, 16
- C08J5/18
- C08F4/63908
- C08F4/63912
- C08F4/63916
- C08F4/63927
- C08F10/00
- C08F10/06
- C08F110/06
- C08F210/16
- C08J2323/04
- C08J2323/10
- D01F6/04
- D01F6/06
- D01F6/30
- Y10S526/901
- Y10S526/902
- IPC, 18
- C08F4 64
- C08F2 34
- C08F2 44
- C08F4 602
- C08F4 639
- C08F4 6392
- C08F4 642
- C08F4 646
- C08F4 6592
- C08F4 68
- C08F10 00
- C08F10 06
- C08F110 06
- C08F210 16
- C08J5 18
- D01F6 04
- D01F6 06
- D01F6 30
Designated states1
- Contracting states, 1
- Netherlands (Kingdom of the)
