CA1333828C - Preparation of propylene/ethylene polymers of the toughened polypropylene type - Google Patents
Preparation of propylene/ethylene polymers of the toughened polypropylene typeInfo
- Publication number
- CA1333828C CA1333828C CA000607986A CA607986A CA1333828C CA 1333828 C CA1333828 C CA 1333828C CA 000607986 A CA000607986 A CA 000607986A CA 607986 A CA607986 A CA 607986A CA 1333828 C CA1333828 C CA 1333828C
- Authority
- CA
- Canada
- Prior art keywords
- stage
- titanium
- polymerization zone
- polymer
- propylene
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 title claims abstract description 32
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 title claims abstract description 26
- -1 polypropylene Polymers 0.000 title claims abstract description 7
- 229920001155 polypropylene Polymers 0.000 title claims description 12
- 229920000573 polyethylene Polymers 0.000 title claims description 8
- 239000004743 Polypropylene Substances 0.000 title claims description 7
- 238000002360 preparation method Methods 0.000 title claims description 5
- 238000006116 polymerization reaction Methods 0.000 claims abstract description 61
- 238000000034 method Methods 0.000 claims abstract description 37
- 229920000642 polymer Polymers 0.000 claims abstract description 37
- 239000010936 titanium Substances 0.000 claims abstract description 30
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 29
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 29
- XJDNKRIXUMDJCW-UHFFFAOYSA-J titanium tetrachloride Chemical compound Cl[Ti](Cl)(Cl)Cl XJDNKRIXUMDJCW-UHFFFAOYSA-J 0.000 claims abstract description 23
- 239000000203 mixture Substances 0.000 claims abstract description 22
- 239000011777 magnesium Substances 0.000 claims abstract description 17
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 16
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 15
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000005977 Ethylene Substances 0.000 claims abstract description 13
- 239000007788 liquid Substances 0.000 claims abstract description 12
- 239000011541 reaction mixture Substances 0.000 claims abstract description 12
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000000460 chlorine Substances 0.000 claims abstract description 11
- 229910000077 silane Inorganic materials 0.000 claims abstract description 11
- 239000000126 substance Substances 0.000 claims abstract description 11
- 229910052801 chlorine Inorganic materials 0.000 claims abstract description 10
- 150000003021 phthalic acid derivatives Chemical class 0.000 claims abstract description 10
- 239000004215 Carbon black (E152) Substances 0.000 claims abstract description 9
- 229930195733 hydrocarbon Natural products 0.000 claims abstract description 9
- 150000002430 hydrocarbons Chemical class 0.000 claims abstract description 9
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229920001384 propylene homopolymer Polymers 0.000 claims abstract description 6
- 239000011954 Ziegler–Natta catalyst Substances 0.000 claims abstract description 5
- 150000004996 alkyl benzenes Chemical class 0.000 claims abstract description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 22
- 239000007790 solid phase Substances 0.000 claims description 19
- 150000002901 organomagnesium compounds Chemical class 0.000 claims description 17
- 229910002027 silica gel Inorganic materials 0.000 claims description 15
- 239000000741 silica gel Substances 0.000 claims description 15
- 238000002156 mixing Methods 0.000 claims description 12
- 125000004432 carbon atom Chemical group C* 0.000 claims description 11
- 239000012320 chlorinating reagent Substances 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- 238000006243 chemical reaction Methods 0.000 claims description 7
- 125000000217 alkyl group Chemical group 0.000 claims description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims description 6
- 239000007791 liquid phase Substances 0.000 claims description 6
- 239000012071 phase Substances 0.000 claims description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 4
- 239000007789 gas Substances 0.000 claims description 4
- 239000001257 hydrogen Substances 0.000 claims description 4
- 239000012429 reaction media Substances 0.000 claims description 4
- 208000036366 Sensation of pressure Diseases 0.000 claims description 3
- LCKIEQZJEYYRIY-UHFFFAOYSA-N Titanium ion Chemical compound [Ti+4] LCKIEQZJEYYRIY-UHFFFAOYSA-N 0.000 claims description 3
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 claims description 3
- WPYMKLBDIGXBTP-UHFFFAOYSA-N benzoic acid Chemical class OC(=O)C1=CC=CC=C1 WPYMKLBDIGXBTP-UHFFFAOYSA-N 0.000 claims description 3
- 238000000605 extraction Methods 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 3
- 229920006395 saturated elastomer Polymers 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 239000010703 silicon Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 2
- 239000003795 chemical substances by application Substances 0.000 claims description 2
- 229910052681 coesite Inorganic materials 0.000 claims description 2
- 229910052593 corundum Inorganic materials 0.000 claims description 2
- 229910052906 cristobalite Inorganic materials 0.000 claims description 2
- 229910052760 oxygen Inorganic materials 0.000 claims description 2
- 239000001301 oxygen Substances 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 235000012239 silicon dioxide Nutrition 0.000 claims description 2
- 229910052682 stishovite Inorganic materials 0.000 claims description 2
- 229910052905 tridymite Inorganic materials 0.000 claims description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 2
- 239000000306 component Substances 0.000 claims 10
- 125000000027 (C1-C10) alkoxy group Chemical group 0.000 claims 1
- 150000001335 aliphatic alkanes Chemical class 0.000 abstract description 4
- 239000007787 solid Substances 0.000 abstract 3
- 229920001400 block copolymer Polymers 0.000 abstract 1
- 238000010924 continuous production Methods 0.000 abstract 1
- 229940095050 propylene Drugs 0.000 description 19
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 12
- 239000000543 intermediate Substances 0.000 description 9
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 8
- YNQLUTRBYVCPMQ-UHFFFAOYSA-N Ethylbenzene Chemical compound CCC1=CC=CC=C1 YNQLUTRBYVCPMQ-UHFFFAOYSA-N 0.000 description 6
- 238000003756 stirring Methods 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 5
- DOIRQSBPFJWKBE-UHFFFAOYSA-N dibutyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCCCC DOIRQSBPFJWKBE-UHFFFAOYSA-N 0.000 description 4
- XNGIFLGASWRNHJ-UHFFFAOYSA-L phthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC=C1C([O-])=O XNGIFLGASWRNHJ-UHFFFAOYSA-L 0.000 description 4
- XFAOZKNGVLIXLC-UHFFFAOYSA-N dimethoxy-(2-methylpropyl)-propan-2-ylsilane Chemical compound CO[Si](C(C)C)(OC)CC(C)C XFAOZKNGVLIXLC-UHFFFAOYSA-N 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 1
- 125000005234 alkyl aluminium group Chemical group 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000012661 block copolymerization Methods 0.000 description 1
- 125000004106 butoxy group Chemical group [*]OC([H])([H])C([H])([H])C(C([H])([H])[H])([H])[H] 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- VHPUZTHRFWIGAW-UHFFFAOYSA-N dimethoxy-di(propan-2-yl)silane Chemical compound CO[Si](OC)(C(C)C)C(C)C VHPUZTHRFWIGAW-UHFFFAOYSA-N 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 1
- 229910000041 hydrogen chloride Inorganic materials 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- KXDANLFHGCWFRQ-UHFFFAOYSA-N magnesium;butane;octane Chemical compound [Mg+2].CCC[CH2-].CCCCCCC[CH2-] KXDANLFHGCWFRQ-UHFFFAOYSA-N 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 238000002411 thermogravimetry Methods 0.000 description 1
- VOITXYVAKOUIBA-UHFFFAOYSA-N triethylaluminium Chemical compound CC[Al](CC)CC VOITXYVAKOUIBA-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
- C08F297/00—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer
- C08F297/06—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the coordination type
- C08F297/08—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the coordination type polymerising mono-olefins
- C08F297/083—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the coordination type polymerising mono-olefins the monomers being ethylene or propylene
Abstract
Propylene/ethylene block co-polymers are prepared by a continuous process in which, in each case in an agitated fixed bed of finely divided polymer from the gas phase, first (I) in a first polymer-ization zone, propylene is homopolymerized by feeding in a Ziegler-Natta catalyst system consisting of (1) a titanium component which contains titanium, magnesium, chlorine and a phthalic acid derivative, (2) an aluminum-alkyl component and (3) a silane component, and (II) in a second polymerization zone, a mixture of propylene and ethylene is polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerization zone by feeding in the said reaction mix-ture. In the process, (A) a titanium component (1) is used which is obtained by a method in which (1.1) first, (1.1.1) in a liquid hydrocarbon, (1.1.2) a finely divided magnesium halide, (1.1.3) an alkanol, (1.1.4) a certain phthalic acid derivative and (1.1.5) titanium tetra-chloride are reacted with one another under certain con-ditions, (1.2) the solid intermediate obtained from (1.1) is extracted with titanium tetrachloride or a liquid alkylbenzene until the remaining solid substance has become substantially richer in magnesium, and (1.3) finally, the solid substance remaining in (1.2) is washed with an alkane in a certain manner, (B) a specific silane is used as (3), and (C) specifically selected polymeriza-tion parameters are employed, with relationships between the first and second polymerization zones.
Description
1 33-382~
O.Z. 0050/40108 Preparation of propylene/ethylene polymers of the toughened polYPropylene type The present invention relates to a process for the continuous preparation of propylene/ethylene polymers of the toughened polypropylene type, in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed of finely divided polymer, in the absence of a liquid reaction medium, from the gas phase, first (A) in a first polymerization zone, propylene is homo-polymerized by feeding in a Ziegler-Natta catalyst system consisting of (1) a titanium component which is based on a finely divided, shape-imparting silica gel and contains titanium, magnesium, chlorine and a benzene-carboxylic acid derivative, (2) an aluminum component of the formula Al R3, where R is alkyl of not more than 8, in particular not more than 4-, carbon atoms, and (3) a silane component of the formula R~Si(OR2) 4-n ~
where Rl is a saturated aliphatic and/or aromatic hydrocarbon radical of not more than 16, preferably not more than 10, carbon atoms, R2 is alkyl of not more than 15, preferably not more than 8, in par-ticular not more than 4, carbon atoms and n is from 0 to 3, preferably from 0 to 2, in particular 1 or 2, with the provisos that (i) the atomic ratio of titanium from the titanium component (1) to aluminum from the aluminumalkyl component (2) is from 1 : 10 to 1 : 500, in particular from 1 : 20 to 1 : 200, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) is from 1 : 0.01 to 1 : 0.5, in particular from 1 : 0.02 to 1 : 0.2 and (iii) from 0.05 to 2, in particular from 0.2 to 1, kg of 3 ~ ~3 ~ 8 - 2 - O.Z. 0050/4010~
polymer are produced per millimole of the aluminum-alkyl component (2), and then (~) in a second polymerization zone, a mixture of propylene and ethylene i9 polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerlzatlon zone by feeding in the sald reactlon mixture.
A process of thi~ type which is particularly interesting in this context has been dlsclosed in U.S.
Patent 4,455,405.
Thi~ proces~ is carried out by a method in which propylene/ethylene polymers are prepared in each case in an agitated fixed bed of flnely dlvided polymer, from the ga~ phase, in two successlve polymerization zones, by feeding in a Ziegler-Natta cataly~t system, under rela-tively mild polymerization condltions in the second poly-merization zone. The process has the disadvantage that the re~ulting products have only moderate notched impact strength~, in particular at low temperatures, owihg to the relatlvely small amounts of polymer formed in the second polymerization zone.
Further processes of the type under discussion have been disclo6ed in a number of variants, and reference nay be made to, for example, U.S. Patent 4,454,299 and South African Patents 0084/3561 2S published October 29, 1984, 0084/3563 published Nov~rber 2, 1984 and 0084/5261 published January lS, 1985, all in the name of BASF A.G., as typical publications.
These known processes and in particular the resulting products have in general proved uatisfactory in indu~try; however, thi~ does not mean that there are not ~till further requirements. Thus, if it i~ intended to produce polymer~ having particularly good performance characteristics, the known proces~es are still su~cep-tible to faults during continuous operation, for example due to the formation of fragments and coatings in the reactor, and/or the polymer~ produced still have a rela-tively high content of undesirable inorganic impuritie~
from the catalyst system used.
r "
- 3 - o.Z. 0050/40108 It is an object of the present invention to im-prove the process defined at the outset in such a way that it has the abovementioned disadvantages only to a considerably reduced extent, if at all.
S We have found that this object is achieved if (~) a particular titanium component (1) is used and (B) the reaction is carried out using specifically selected polymerization parameters and relationships between the first and second polymerization zones.
The present invention accordingly relates to a process for the continuous preparation of propyl-ene/ethylene polymers of the toughened polypropylene type, in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed of finely divided polymer (which is known technically to mean a bed of finely divided polymer which is kept in movement by stirring), in the absence of a liquid reac-tion medium, from the gas phase, first (A) in a first polymerization zone, propylene is homo-polymerized by feeding in a Ziegler-Natta catalyst system consisting of (1) a titanium component which is based on a finely divided, shape-imparting silica gel and contains titanium, magnesium, chlorine and a benzene-carboxylic acid derivative, (2) an aluminum component of the formula Al R3, where R is alkyl of not more than 8, in particular not more than 4, carbon atoms, and (3) a silane component of the formula RlnS i ( oR2 ) 4-n ~
where R1 is a saturated aliphatic and/or aromatic hydrocarbon radical of not more than 16, preferably not more than 10, carbon atoms, R2 is alkyl of not more than 15, preferably not more than 8, in par-ticular not more than 4, carbon atoms and n is from 0 to 3, preferably from 0 to 2, in particular 1 or 1 ~33828 - 4 - O.Z. 0050/40108 with the provisos that (i) the atomic ratio of titanium from the titanium component (1) to aluminum from the aluminumalkyl component (2) is from 1 : 10 to 1 : 500, in particular from 1 : 20 to 1 : 200, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) is from 1 : 0.01 to 1 : 0.5, in particular from 1 : 0.02 to 1 : 0.2 and (iii) from 0.05 to 2, in particular from 0.2 to 1, kg of polymer are produced per millimole of the aluminum-alkyl component (2), and then (B) in a second polymerization zone, a mixture of propylene and ethylene is polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerization zone by feeding in the said reaction mixture.
In the novel process, ( ~ ) the titanium component (1) used is one which is obtained by a method in which first (1.1) in a first stage (I) a carrier is prepared from (Ia) a finely divided silica gel which has a particle diameter of from 1 to 1,000, preferably from 5 to 500, in particular from 10 to 200, ~m, a pore volume of from 0.3 to 5.0, in particular from 1.0 to 3.0, cm3/g and a surface area of from 100 to 1,000, in particular from 200 to 500, m2/g, is of the formula SiO2 . a Al2O3, where a is from 0 to 2, in particular from 0 to 0.5, and has a moisture content such that it loses from 1 to 20, preferably from 2 to 15, in particular from 4 to 10, % by weight, based on the initial total weight of the silica gel, of water at 1000C in the course of 0.5 hour, (Ib) an organo-magnesium compound of the formula MgR3R4, where R3 and R4 are each C2-C10-alkyl, preferably C4-C~-alkyl, and (Ic) a gaseous chlorinating agent of the formula ClZ, where Z is Cl or H, preferably H, by a method in which first (1.1.1) in a first sub-stage, in a liquid inert ~ 3 3 ~ ~ ~
O.Z. 0050/40108 Preparation of propylene/ethylene polymers of the toughened polYPropylene type The present invention relates to a process for the continuous preparation of propylene/ethylene polymers of the toughened polypropylene type, in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed of finely divided polymer, in the absence of a liquid reaction medium, from the gas phase, first (A) in a first polymerization zone, propylene is homo-polymerized by feeding in a Ziegler-Natta catalyst system consisting of (1) a titanium component which is based on a finely divided, shape-imparting silica gel and contains titanium, magnesium, chlorine and a benzene-carboxylic acid derivative, (2) an aluminum component of the formula Al R3, where R is alkyl of not more than 8, in particular not more than 4-, carbon atoms, and (3) a silane component of the formula R~Si(OR2) 4-n ~
where Rl is a saturated aliphatic and/or aromatic hydrocarbon radical of not more than 16, preferably not more than 10, carbon atoms, R2 is alkyl of not more than 15, preferably not more than 8, in par-ticular not more than 4, carbon atoms and n is from 0 to 3, preferably from 0 to 2, in particular 1 or 2, with the provisos that (i) the atomic ratio of titanium from the titanium component (1) to aluminum from the aluminumalkyl component (2) is from 1 : 10 to 1 : 500, in particular from 1 : 20 to 1 : 200, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) is from 1 : 0.01 to 1 : 0.5, in particular from 1 : 0.02 to 1 : 0.2 and (iii) from 0.05 to 2, in particular from 0.2 to 1, kg of 3 ~ ~3 ~ 8 - 2 - O.Z. 0050/4010~
polymer are produced per millimole of the aluminum-alkyl component (2), and then (~) in a second polymerization zone, a mixture of propylene and ethylene i9 polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerlzatlon zone by feeding in the sald reactlon mixture.
A process of thi~ type which is particularly interesting in this context has been dlsclosed in U.S.
Patent 4,455,405.
Thi~ proces~ is carried out by a method in which propylene/ethylene polymers are prepared in each case in an agitated fixed bed of flnely dlvided polymer, from the ga~ phase, in two successlve polymerization zones, by feeding in a Ziegler-Natta cataly~t system, under rela-tively mild polymerization condltions in the second poly-merization zone. The process has the disadvantage that the re~ulting products have only moderate notched impact strength~, in particular at low temperatures, owihg to the relatlvely small amounts of polymer formed in the second polymerization zone.
Further processes of the type under discussion have been disclo6ed in a number of variants, and reference nay be made to, for example, U.S. Patent 4,454,299 and South African Patents 0084/3561 2S published October 29, 1984, 0084/3563 published Nov~rber 2, 1984 and 0084/5261 published January lS, 1985, all in the name of BASF A.G., as typical publications.
These known processes and in particular the resulting products have in general proved uatisfactory in indu~try; however, thi~ does not mean that there are not ~till further requirements. Thus, if it i~ intended to produce polymer~ having particularly good performance characteristics, the known proces~es are still su~cep-tible to faults during continuous operation, for example due to the formation of fragments and coatings in the reactor, and/or the polymer~ produced still have a rela-tively high content of undesirable inorganic impuritie~
from the catalyst system used.
r "
- 3 - o.Z. 0050/40108 It is an object of the present invention to im-prove the process defined at the outset in such a way that it has the abovementioned disadvantages only to a considerably reduced extent, if at all.
S We have found that this object is achieved if (~) a particular titanium component (1) is used and (B) the reaction is carried out using specifically selected polymerization parameters and relationships between the first and second polymerization zones.
The present invention accordingly relates to a process for the continuous preparation of propyl-ene/ethylene polymers of the toughened polypropylene type, in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed of finely divided polymer (which is known technically to mean a bed of finely divided polymer which is kept in movement by stirring), in the absence of a liquid reac-tion medium, from the gas phase, first (A) in a first polymerization zone, propylene is homo-polymerized by feeding in a Ziegler-Natta catalyst system consisting of (1) a titanium component which is based on a finely divided, shape-imparting silica gel and contains titanium, magnesium, chlorine and a benzene-carboxylic acid derivative, (2) an aluminum component of the formula Al R3, where R is alkyl of not more than 8, in particular not more than 4, carbon atoms, and (3) a silane component of the formula RlnS i ( oR2 ) 4-n ~
where R1 is a saturated aliphatic and/or aromatic hydrocarbon radical of not more than 16, preferably not more than 10, carbon atoms, R2 is alkyl of not more than 15, preferably not more than 8, in par-ticular not more than 4, carbon atoms and n is from 0 to 3, preferably from 0 to 2, in particular 1 or 1 ~33828 - 4 - O.Z. 0050/40108 with the provisos that (i) the atomic ratio of titanium from the titanium component (1) to aluminum from the aluminumalkyl component (2) is from 1 : 10 to 1 : 500, in particular from 1 : 20 to 1 : 200, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) is from 1 : 0.01 to 1 : 0.5, in particular from 1 : 0.02 to 1 : 0.2 and (iii) from 0.05 to 2, in particular from 0.2 to 1, kg of polymer are produced per millimole of the aluminum-alkyl component (2), and then (B) in a second polymerization zone, a mixture of propylene and ethylene is polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerization zone by feeding in the said reaction mixture.
In the novel process, ( ~ ) the titanium component (1) used is one which is obtained by a method in which first (1.1) in a first stage (I) a carrier is prepared from (Ia) a finely divided silica gel which has a particle diameter of from 1 to 1,000, preferably from 5 to 500, in particular from 10 to 200, ~m, a pore volume of from 0.3 to 5.0, in particular from 1.0 to 3.0, cm3/g and a surface area of from 100 to 1,000, in particular from 200 to 500, m2/g, is of the formula SiO2 . a Al2O3, where a is from 0 to 2, in particular from 0 to 0.5, and has a moisture content such that it loses from 1 to 20, preferably from 2 to 15, in particular from 4 to 10, % by weight, based on the initial total weight of the silica gel, of water at 1000C in the course of 0.5 hour, (Ib) an organo-magnesium compound of the formula MgR3R4, where R3 and R4 are each C2-C10-alkyl, preferably C4-C~-alkyl, and (Ic) a gaseous chlorinating agent of the formula ClZ, where Z is Cl or H, preferably H, by a method in which first (1.1.1) in a first sub-stage, in a liquid inert ~ 3 3 ~ ~ ~
- 5 - O.Z. 0050/40108 hydrocarbon, in particular an alkane, with constant thorough mixing at from 10 to 120C, in particular from 20 to 100C, the finely divided silica gel (Ia) and the organomagnesium compound (Ib) are combined, from 1 to 10, in particular from 1.5 to 5, molar parts of the organo-magnesium compound (Ib) being used per 10 molar parts of silicon of the silica gel (Ia), and the combined sub-stances are kept at from 20 to 140C, in particular from 60 to 90C, for from 0.5 to 5, in particular from 1 to 2, hours, then (1.1.2) in a second sub-stage, with constant thorough mixing at from -20 to +80C, in particular from 0 to +60C, the gaseous chlorinating agent (Ic) is passed into the mixture obtained from the first sub-stage, from 2 to 40, in particular from 5 to 20, molar parts of the chlorinating agent (Ic) being used per molar part of the organomagnesium compound (Ib), the entire mixture is left at a temperature in the stated range for from 0.5 to hours, in particular from 0.5 to 1 hour, and the resulting solid-phase product, ie. the carrier (I), is isolated with removal of the liquid phase, thereafter (1.2) in a second stage, a solid-phase intermediate is prepared from (I) the carrier obtained in the first stage, (II) a Cl-C8-alkanol, in particular ethanol, (III) titanium tetrachloride and (IV) a phthalic acid deriva-tive of the formula ~-~x '~c~Y
where X and Y together are oxygen or X and Y are each chlorine or Cl-C10-alkoxy, preferably Cl-C8-alkoxy, in par-ticular butoxy, by a method in which first (1.2.1) in a first sub-stage, in a liquid inert hydro-carbon, in particular an alkane, with constant thorough mixing at room temperature, the carrier (I) and the alkanol (II) are combined, from 1 to 5, in particular from 2.5 to 3.5, molar parts of the alkanol (II) being - 6 - O.Z. 0050/40108 used per molar part of magnesium of the carrier (I), and the combined substances are kept at from 20 to 140C, in particular from 70 to 90C, for from 0.5 to 5, in par-ticular from 1 to 2, hours, then (1.2.2) in a second sub-stage, with constant thorough mixing at room temperature, the titanium tetrachloride (III) is introduced into the reaction mixture resulting from the first sub-stage, from 2 to 20, in particular from 4 to 8, molar parts of the titanium tetrachloride (III) being used per molar part of magnesium of the car-rier (I), the combined substances are kept at from 10 to 150C, in particular from 90 to 120C, for from 0.5 to 5, in particular from 1 to 2, hours, and the resulting solid-phase intermediate is isolated with removal of the liquid phase, with the proviso that the phthalic acid derivative (IV) is introduced in the course of one or both of the sub-stages (1.2.1) and (1.2.2), from 0.01 to 1, preferably from 0.1 to 0.8, in particular from 0.2 to 0.6, molar part of the phthalic acid derivative (IV) being used per molar part of magnesium of the carrier (I), then (1.3) in a third stage, the solid-phase intermediate obtained from the second stage is subjected, at from 100 to 150C, in particular from 115 to 135C, for from 0.2 to S, in particular from 1.5 to 3, hours, to a single-stage, multistage or continuous extraction with titanium tetrachloride or a mixture of titanium tetrachloride and an alkylbenzene of not more than 12, preferably not more than 10, carbon atoms, in particular ethylbenzene, which contains not less than 5, in particular not less than 10, ~ by weight of titanium tetrachloride, a total of from 10 to 1,000, preferably from 20 to 800, in particular from 40 to 300, parts by weight of the extracting agent being used per 10 parts by weight of the solid-phase inter-mediate obtained from the second stage, and finally (1.4) in a fourth stage, the solid-phase product formed in the third stage is washed with a liquid inert - 7 - O.Z. 0050/40108 hydrocarbon, in particular an alkane, until the hydro-carbon contains less than 2, preferably less than 1, % by weight of titanium tetrachloride, and the titanium component (1) is thus obtained, and (~) polymerization is carried out by a method in which (a) in the first polymerization zone, the reaction is carried out under a total pressure of from 20 to 40, preferably from 22 to 35, bar and at from 60 to 90C, preferably from 65 to 80C, with the proviso that the mean residence time of the polymer is from 1.5 to 5, preferably from 2.5 to 4, hours, (b) in the second polymerization zone, the reaction is carried out under a total pressure of from 7 to 25, preferably from 11 to 20, bar and at from 40 to 70C, preferably from 50 to 60C, with the proviso that the ratio of the propylene partial pressure to the ethylene partial pressure is from 100 : 20 to 100 : 120, preferably from 100 : 30 to 100 : 60, (c) the total pressure in the first polymerization zone is kept at least 7 bar higher than the total pres-sure in the second polymerization zone, (d) the ratio of the weight of the propylene converted into polymer in the first polymerization zone to the weight of the propylene/ethylene mixture converted into polymer in the second polymerization zone is from 100 : 40 to 100 : 150, in particular from 100 : 50 to 100 : 130, and (e) the mean residence time of the polymer in the second polymerization zone is equal to the mean residence time of the polymer in the first polymerization zone multiplied by 0.8-1.2, preferably 0.9-1.1, times the quotient of the amount of polymer discharged per hour from the first polymerization zone and the amount of polymer discharged per hour from the second polymerization zone.
~ 333828 - 8 - O.Z. 0050/40108 Regarding the novel process, the following may be noted specifically:
Provided that the defining features are taken into account, the polymerization process as such can be 5carried out in virtually any relevant conventional tech-nological embodiment. These embodiments, ie. the tech-nological variants of the continuous gas-phase block copolymerization of propylene/ethylene in two polymeriza-tion zones by the Ziegler-Natta method, are well known.
10Their development is reflected in the processes as dis-closed first in British Patent 837,301, then in British Patent 1,006,469 and finally in British Patent 1,032,945, and it has proven advantageous to design each of the stages (I) and (II) of the process from the last-15mentioned patent to correspond to the single stage of the process disclosed in British Patent 1,354,020.
Particular embodiments of the process under dis-cussion, of a type to which the novel process also belongs, are likewise disclosed, for example by the U.S.
20Patent 4,454,299 and the South African Patents 0084/3561, 0084/3563 and 0084/5261 cited at the outset.
Further explanations of the novel polymerization process as such are therefore unnecessary.
For the sake of completeness, it should however 25be mentioned that, in the novel process, the components of the catalyst system can be introduced into the first polymerization zone in a variety of ways, for example (i) the titanium component (1), the aluminumalkyl component (2) and the further catalyst component (3) all at the 30same point together, (ii) the same components all at different points, (iii) component (1) on the one hand and a mixture of components (2) and (3) on the other hand at different points, which may be particularly advantageous, or (iv) a mixture of components (1) and (3) on the one 35hand and component (2) on the other hand at different points.
Regarding the composition of the catalyst system '1 J 33828 _ g - O.Z. 0050/40108 to be used in the novel process, the following may be stated specifically:
(1) The titanium component is of a particular type; it is defined specifically above.
(2) The alkylaluminum component may be a relevant con-ventional one corresponding to the definition given above; triethylaluminum is preferred.
(3) The further catalyst component is a special silane of the above formula; the silane may be, in this respect, a relevant conventional one.
For the purposes of the present invention, toluyltriethoxysilane, diisopropyldimethoxysilane and isobutylisopropyldimethoxysilane have provenparticularly useful.
EXAMPLE
In a relevant conventional apparatus (ie. a cascade; cf. British Patent 1,032,945), a propyl-ene/ethylene polymer of the toughened polypropylene type was prepared continuously by a method in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed (a stirred concentric fixed bed) of finely divided polymer and in the absence of a liquid reaction medium, from the gas phase, first (A) in a first polymerization zone having an effective volume of 180 1, propylene was homopolymerized by feeding in, continuously and separately, a Ziegler-Natta catalyst system consisting of (1) a titanium component, (2) aluminumtriethyl and (3) isobutylisopropyldimethoxysilane, with the provisos that (i) the atomic ratio of titanium from the titanium component (1) to aluminum from the aluminumalkyl component (2) was 1 : 100, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) was 1 : 0.1 and (iii) 0.4 kg of polymer was produced per millimole of the aluminumalkyl component (2), and then ~ ~33828 - 10 - O.Z. 0050/40108 (B) in a second polymerization zone having an effective volume of 180 1, a mixture of propylene and ethylene was polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerization zone by feeding in the said reaction mixture.
According to the invention, the process was car-ried out specifically as follows:
(~) the titanium component (1) used was one which was ob-tained by a method in which first (1.1) in a first stage (I) a carrier was prepared from (Ia) a finely divided silica gel which had a particle diameter of from 20 to 45 ~m, a pore volume of 1.75 cm3/g and a surface area of 320 m2/g, was of the formula SiOz and had a moisture content such that it lost 7.4% by weight, based on the initial total weight of the silica gel, of water at 1000C in the course of 0.5 hour (method of measurement: differential thermogravimetry), (Ib) butyloctylmagnesium and (Ic) hydrogen chloride, by a method in which first (1.1.1) in a first sub-stage, in n-heptane, with constant thorough mixing by means of stirring at room temperature, the finely divided silica gel (Ia) and the organomag-nesium compound (Ib) were combined, 3.3 molar parts of the organomagnesium compound (Ib) being used per 10 molar parts of silicon of the silica gel (Ia), and the combined substances were kept at about 90C for 1.5 hours, then (1.1.2) in a second sub-stage, with constant thorough mixing by means of stirring at about 20C, the gaseous chlorinating agent (Ic) was passed into the mixture ob-tained from the first sub-stage, 10 molar parts of the chlorinating agent (Ic) being used per molar part of the organomagnesium compound (Ib), the entire mixture was left at a temperature in the stated range for 0.5 hour and the resulting solid-phase product, ie. the carrier (I), was isolated with removal of the liquid phase, ~ J33~28 - 11 - O.Z. 0050/40108 thereafter (1.2) in a second stage, a solid-phase intermediate was prepared from (I) the carrier obtained in the first stage, (II) ethanol, (III) titanium tetrachloride and (IV) di-n-butyl phthalate, by a method in which first (1.2.1) in a first sub-stage, in n-heptane, with constant thorough mixing by means of stirring at room temperature, the carrier (I) and the ethanol (II) were combined, 3 molar parts of the ethanol (II) being used per molar part of magnesium of the carrier (I), and the combined substances were kept at about 80C for 1.5 hours, then (1.2.2) in a second sub-stage, with constant thorough mixing by means of stirring at room temperature, the titanium tetrachloride (III) was introduced into the reaction mixture resulting from the first sub-stage, 6 molar parts of the titanium tetrachloride (III) being used per molar part of magnesium of the carrier (I), and then the di-n-butyl phthalate was introduced, 0.50 molar part of the phthalate (IV) being used per molar part of magnesium of the carrier (I), the combined substances were kept at about 120C for 2 hours while stirring, and the resulting solid-phase intermediate was isolated with removal of the liquid phase by filtration under suction, then (1.3) in a third stage, the solid-phase intermediate obtained from the second stage was subjected, at 125C, for 2 hours, to a continuous extraction with a mixture of titanium tetrachloride and ethylbenzene, which contains 15% by weight of titanium tetrachloride, 140 parts by weight of the titanium tetrachloride/ethylbenzene mixture being used per 10 parts by weight of the solid-phase intermediate obtained from the second stage, after which the resulting solid-phase intermediate was isolated by filtration, and finally (1.4) in a fourth stage, the solid-phase product ob-tained in the third stage was washed with n-heptane until the n-heptane contained less than 0.3% by weight of ~ ~3382~
- 12 - O.Z. 0050/40108 titanium tetrachloride, and the titanium component (1) was thus obtained; it contained 3.1% by weight of titan-ium, 7.5% by weight of magnesium and 28.3% by weight of chlorine.
(~) Furthermore, polymerization was carried out by a method in which (a) in the first polymerization zone, the reaction was carried out under a total pressure of 28 bar and at 70C, with the proviso that the mean residence time of the polymer was 3.0 hours, (b) in the second polymerization zone, the reaction was carried out under a total pressure of 20 bar and at 60C, with the proviso that the ratio of the propyl-ene partial pressure to the ethylene partial pres-sure was 100 : 43, (c) the total pressure in the first polymerization zone was thus kept 8 bar higher than the total pressure in the second polymerization zone, (d) the ratio of the propylene converted into polymer in the first polymerization zone to the weight of the propylene/ethylene mixture converted into polymer in the second polymerization zone was 100 : 105 and (e) the mean residence time of the polymer in the second polymerization zone (1.47 hours) was equal to the mean residence time of the polymer in the first polymerization zone (3.0 hours), multiplied by the quotient of the amount of polymer discharged hourly from the first polymerization zone (15.1 kg/h) and the amount of polymer discharged hourly from the second polymerization zone (30.9 kg/h), ie. 1.47 =
3.0 x 1 x 15.1 : 30.9 kg/h.
In this procedure, a propylene homopolymer having a melt flow index (measured at 230C, 2.16 kg) of 8 g/10' was formed in the first polymerization zone and a polymer having a melt flow index of 1.4 g/10' was formed in the second polymerization zone.
- 13 - O.Z. 0050/40108 The continuous operation for the production of the propylene/ethylene polymer of the toughened polyprop-ylene type could be carried out without problemæ in the manner described; furthermore the product obtained had a low content of inorganic impurities, in particular of chlorine and titanium; analysis of this product gave the following:
Ti : ~ 1 ppm, Cl : 6 ppm, Al : 82 ppm, Mg : 2 ppm, Si : 3 ppm.
The physical properties of the polymer obtained are shown in the Table below.
! 3 33~32('3 - 14 - O. Z . 0050/40108 O E C _ ~
3 a~ Z
O
_I O
.
s~ C ~ C ~
~a s~ _ ~ , CO
o .1 ` ~ dP
~ -- ~
.,~ o ~1 o d~
I ~
O
~ o ,i ~
0 o O I dP
O
~ U~
P~ ,, U~
U~ Z ~ Z Z
N O a ~ ~ a a O o ~ ~ o o V _ J~
a ~D . ~ ~
O ~ o o a~ oo O O
-' C ~ _l ~ ~ U U
~ a~ o _I ~ ~ ~r ~ _ _ _ _ a~ ~ ~ ~ ,a u ~ ~
,4 _____
where X and Y together are oxygen or X and Y are each chlorine or Cl-C10-alkoxy, preferably Cl-C8-alkoxy, in par-ticular butoxy, by a method in which first (1.2.1) in a first sub-stage, in a liquid inert hydro-carbon, in particular an alkane, with constant thorough mixing at room temperature, the carrier (I) and the alkanol (II) are combined, from 1 to 5, in particular from 2.5 to 3.5, molar parts of the alkanol (II) being - 6 - O.Z. 0050/40108 used per molar part of magnesium of the carrier (I), and the combined substances are kept at from 20 to 140C, in particular from 70 to 90C, for from 0.5 to 5, in par-ticular from 1 to 2, hours, then (1.2.2) in a second sub-stage, with constant thorough mixing at room temperature, the titanium tetrachloride (III) is introduced into the reaction mixture resulting from the first sub-stage, from 2 to 20, in particular from 4 to 8, molar parts of the titanium tetrachloride (III) being used per molar part of magnesium of the car-rier (I), the combined substances are kept at from 10 to 150C, in particular from 90 to 120C, for from 0.5 to 5, in particular from 1 to 2, hours, and the resulting solid-phase intermediate is isolated with removal of the liquid phase, with the proviso that the phthalic acid derivative (IV) is introduced in the course of one or both of the sub-stages (1.2.1) and (1.2.2), from 0.01 to 1, preferably from 0.1 to 0.8, in particular from 0.2 to 0.6, molar part of the phthalic acid derivative (IV) being used per molar part of magnesium of the carrier (I), then (1.3) in a third stage, the solid-phase intermediate obtained from the second stage is subjected, at from 100 to 150C, in particular from 115 to 135C, for from 0.2 to S, in particular from 1.5 to 3, hours, to a single-stage, multistage or continuous extraction with titanium tetrachloride or a mixture of titanium tetrachloride and an alkylbenzene of not more than 12, preferably not more than 10, carbon atoms, in particular ethylbenzene, which contains not less than 5, in particular not less than 10, ~ by weight of titanium tetrachloride, a total of from 10 to 1,000, preferably from 20 to 800, in particular from 40 to 300, parts by weight of the extracting agent being used per 10 parts by weight of the solid-phase inter-mediate obtained from the second stage, and finally (1.4) in a fourth stage, the solid-phase product formed in the third stage is washed with a liquid inert - 7 - O.Z. 0050/40108 hydrocarbon, in particular an alkane, until the hydro-carbon contains less than 2, preferably less than 1, % by weight of titanium tetrachloride, and the titanium component (1) is thus obtained, and (~) polymerization is carried out by a method in which (a) in the first polymerization zone, the reaction is carried out under a total pressure of from 20 to 40, preferably from 22 to 35, bar and at from 60 to 90C, preferably from 65 to 80C, with the proviso that the mean residence time of the polymer is from 1.5 to 5, preferably from 2.5 to 4, hours, (b) in the second polymerization zone, the reaction is carried out under a total pressure of from 7 to 25, preferably from 11 to 20, bar and at from 40 to 70C, preferably from 50 to 60C, with the proviso that the ratio of the propylene partial pressure to the ethylene partial pressure is from 100 : 20 to 100 : 120, preferably from 100 : 30 to 100 : 60, (c) the total pressure in the first polymerization zone is kept at least 7 bar higher than the total pres-sure in the second polymerization zone, (d) the ratio of the weight of the propylene converted into polymer in the first polymerization zone to the weight of the propylene/ethylene mixture converted into polymer in the second polymerization zone is from 100 : 40 to 100 : 150, in particular from 100 : 50 to 100 : 130, and (e) the mean residence time of the polymer in the second polymerization zone is equal to the mean residence time of the polymer in the first polymerization zone multiplied by 0.8-1.2, preferably 0.9-1.1, times the quotient of the amount of polymer discharged per hour from the first polymerization zone and the amount of polymer discharged per hour from the second polymerization zone.
~ 333828 - 8 - O.Z. 0050/40108 Regarding the novel process, the following may be noted specifically:
Provided that the defining features are taken into account, the polymerization process as such can be 5carried out in virtually any relevant conventional tech-nological embodiment. These embodiments, ie. the tech-nological variants of the continuous gas-phase block copolymerization of propylene/ethylene in two polymeriza-tion zones by the Ziegler-Natta method, are well known.
10Their development is reflected in the processes as dis-closed first in British Patent 837,301, then in British Patent 1,006,469 and finally in British Patent 1,032,945, and it has proven advantageous to design each of the stages (I) and (II) of the process from the last-15mentioned patent to correspond to the single stage of the process disclosed in British Patent 1,354,020.
Particular embodiments of the process under dis-cussion, of a type to which the novel process also belongs, are likewise disclosed, for example by the U.S.
20Patent 4,454,299 and the South African Patents 0084/3561, 0084/3563 and 0084/5261 cited at the outset.
Further explanations of the novel polymerization process as such are therefore unnecessary.
For the sake of completeness, it should however 25be mentioned that, in the novel process, the components of the catalyst system can be introduced into the first polymerization zone in a variety of ways, for example (i) the titanium component (1), the aluminumalkyl component (2) and the further catalyst component (3) all at the 30same point together, (ii) the same components all at different points, (iii) component (1) on the one hand and a mixture of components (2) and (3) on the other hand at different points, which may be particularly advantageous, or (iv) a mixture of components (1) and (3) on the one 35hand and component (2) on the other hand at different points.
Regarding the composition of the catalyst system '1 J 33828 _ g - O.Z. 0050/40108 to be used in the novel process, the following may be stated specifically:
(1) The titanium component is of a particular type; it is defined specifically above.
(2) The alkylaluminum component may be a relevant con-ventional one corresponding to the definition given above; triethylaluminum is preferred.
(3) The further catalyst component is a special silane of the above formula; the silane may be, in this respect, a relevant conventional one.
For the purposes of the present invention, toluyltriethoxysilane, diisopropyldimethoxysilane and isobutylisopropyldimethoxysilane have provenparticularly useful.
EXAMPLE
In a relevant conventional apparatus (ie. a cascade; cf. British Patent 1,032,945), a propyl-ene/ethylene polymer of the toughened polypropylene type was prepared continuously by a method in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed (a stirred concentric fixed bed) of finely divided polymer and in the absence of a liquid reaction medium, from the gas phase, first (A) in a first polymerization zone having an effective volume of 180 1, propylene was homopolymerized by feeding in, continuously and separately, a Ziegler-Natta catalyst system consisting of (1) a titanium component, (2) aluminumtriethyl and (3) isobutylisopropyldimethoxysilane, with the provisos that (i) the atomic ratio of titanium from the titanium component (1) to aluminum from the aluminumalkyl component (2) was 1 : 100, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) was 1 : 0.1 and (iii) 0.4 kg of polymer was produced per millimole of the aluminumalkyl component (2), and then ~ ~33828 - 10 - O.Z. 0050/40108 (B) in a second polymerization zone having an effective volume of 180 1, a mixture of propylene and ethylene was polymerized with the propylene homopolymer present in the reaction mixture obtained in the first polymerization zone by feeding in the said reaction mixture.
According to the invention, the process was car-ried out specifically as follows:
(~) the titanium component (1) used was one which was ob-tained by a method in which first (1.1) in a first stage (I) a carrier was prepared from (Ia) a finely divided silica gel which had a particle diameter of from 20 to 45 ~m, a pore volume of 1.75 cm3/g and a surface area of 320 m2/g, was of the formula SiOz and had a moisture content such that it lost 7.4% by weight, based on the initial total weight of the silica gel, of water at 1000C in the course of 0.5 hour (method of measurement: differential thermogravimetry), (Ib) butyloctylmagnesium and (Ic) hydrogen chloride, by a method in which first (1.1.1) in a first sub-stage, in n-heptane, with constant thorough mixing by means of stirring at room temperature, the finely divided silica gel (Ia) and the organomag-nesium compound (Ib) were combined, 3.3 molar parts of the organomagnesium compound (Ib) being used per 10 molar parts of silicon of the silica gel (Ia), and the combined substances were kept at about 90C for 1.5 hours, then (1.1.2) in a second sub-stage, with constant thorough mixing by means of stirring at about 20C, the gaseous chlorinating agent (Ic) was passed into the mixture ob-tained from the first sub-stage, 10 molar parts of the chlorinating agent (Ic) being used per molar part of the organomagnesium compound (Ib), the entire mixture was left at a temperature in the stated range for 0.5 hour and the resulting solid-phase product, ie. the carrier (I), was isolated with removal of the liquid phase, ~ J33~28 - 11 - O.Z. 0050/40108 thereafter (1.2) in a second stage, a solid-phase intermediate was prepared from (I) the carrier obtained in the first stage, (II) ethanol, (III) titanium tetrachloride and (IV) di-n-butyl phthalate, by a method in which first (1.2.1) in a first sub-stage, in n-heptane, with constant thorough mixing by means of stirring at room temperature, the carrier (I) and the ethanol (II) were combined, 3 molar parts of the ethanol (II) being used per molar part of magnesium of the carrier (I), and the combined substances were kept at about 80C for 1.5 hours, then (1.2.2) in a second sub-stage, with constant thorough mixing by means of stirring at room temperature, the titanium tetrachloride (III) was introduced into the reaction mixture resulting from the first sub-stage, 6 molar parts of the titanium tetrachloride (III) being used per molar part of magnesium of the carrier (I), and then the di-n-butyl phthalate was introduced, 0.50 molar part of the phthalate (IV) being used per molar part of magnesium of the carrier (I), the combined substances were kept at about 120C for 2 hours while stirring, and the resulting solid-phase intermediate was isolated with removal of the liquid phase by filtration under suction, then (1.3) in a third stage, the solid-phase intermediate obtained from the second stage was subjected, at 125C, for 2 hours, to a continuous extraction with a mixture of titanium tetrachloride and ethylbenzene, which contains 15% by weight of titanium tetrachloride, 140 parts by weight of the titanium tetrachloride/ethylbenzene mixture being used per 10 parts by weight of the solid-phase intermediate obtained from the second stage, after which the resulting solid-phase intermediate was isolated by filtration, and finally (1.4) in a fourth stage, the solid-phase product ob-tained in the third stage was washed with n-heptane until the n-heptane contained less than 0.3% by weight of ~ ~3382~
- 12 - O.Z. 0050/40108 titanium tetrachloride, and the titanium component (1) was thus obtained; it contained 3.1% by weight of titan-ium, 7.5% by weight of magnesium and 28.3% by weight of chlorine.
(~) Furthermore, polymerization was carried out by a method in which (a) in the first polymerization zone, the reaction was carried out under a total pressure of 28 bar and at 70C, with the proviso that the mean residence time of the polymer was 3.0 hours, (b) in the second polymerization zone, the reaction was carried out under a total pressure of 20 bar and at 60C, with the proviso that the ratio of the propyl-ene partial pressure to the ethylene partial pres-sure was 100 : 43, (c) the total pressure in the first polymerization zone was thus kept 8 bar higher than the total pressure in the second polymerization zone, (d) the ratio of the propylene converted into polymer in the first polymerization zone to the weight of the propylene/ethylene mixture converted into polymer in the second polymerization zone was 100 : 105 and (e) the mean residence time of the polymer in the second polymerization zone (1.47 hours) was equal to the mean residence time of the polymer in the first polymerization zone (3.0 hours), multiplied by the quotient of the amount of polymer discharged hourly from the first polymerization zone (15.1 kg/h) and the amount of polymer discharged hourly from the second polymerization zone (30.9 kg/h), ie. 1.47 =
3.0 x 1 x 15.1 : 30.9 kg/h.
In this procedure, a propylene homopolymer having a melt flow index (measured at 230C, 2.16 kg) of 8 g/10' was formed in the first polymerization zone and a polymer having a melt flow index of 1.4 g/10' was formed in the second polymerization zone.
- 13 - O.Z. 0050/40108 The continuous operation for the production of the propylene/ethylene polymer of the toughened polyprop-ylene type could be carried out without problemæ in the manner described; furthermore the product obtained had a low content of inorganic impurities, in particular of chlorine and titanium; analysis of this product gave the following:
Ti : ~ 1 ppm, Cl : 6 ppm, Al : 82 ppm, Mg : 2 ppm, Si : 3 ppm.
The physical properties of the polymer obtained are shown in the Table below.
! 3 33~32('3 - 14 - O. Z . 0050/40108 O E C _ ~
3 a~ Z
O
_I O
.
s~ C ~ C ~
~a s~ _ ~ , CO
o .1 ` ~ dP
~ -- ~
.,~ o ~1 o d~
I ~
O
~ o ,i ~
0 o O I dP
O
~ U~
P~ ,, U~
U~ Z ~ Z Z
N O a ~ ~ a a O o ~ ~ o o V _ J~
a ~D . ~ ~
O ~ o o a~ oo O O
-' C ~ _l ~ ~ U U
~ a~ o _I ~ ~ ~r ~ _ _ _ _ a~ ~ ~ ~ ,a u ~ ~
,4 _____
Claims
1. A process for the continuous preparation of a propylene/ethylene polymer of the toughened polypropylene type, in which, in each case in the presence of hydrogen as a molecular weight regulator, in an agitated fixed bed of finely divided polymer, in the absence of a liquid reaction medium, from the gas phase, first (A) in a first polymerization zone, propylene is homo-polymerized by feeding in a Ziegler-Natta catalyst system consisting of (1) a titanium component which is based on a finely divided, shape-imparting silica gel and contains titanium, magnesium, chlorine and a benzenecarbox-ylic acid derivative, (2) an aluminum component of the formula Al R3, where R is alkyl of not more than 8 carbon atoms, and (3) a silane component of the formula , where R1 is a saturated aliphatic and/or aromatic hydrocarbon radical of not more than 16 carbon atoms, R2 is alkyl of not more than 15 carbon atoms and n is from 0 to 3, with the provisos that (i) the atomic ratio of titanium from the titanium component (l) to aluminum from the aluminumalkyl component (2) is from 1 : 10 to 1 : 500, (ii) the molar ratio of aluminumalkyl component (2) to silane component (3) is from 1 : 0.01 to 1 : 0.5 and (iii) from 0.05 to 2 kg of polymer are produced per millimole of the aluminum-alkyl component (2), and then (B) in a second polymerization zone, a mixture of propylene and ethylene is polymerized with the propylene homopolymer present in the reaction mix-ture obtained in the first polymerization zone by feeding in the said reaction mixture, wherein (.alpha.) the titanium component (1) used is one which is obtained by a method in which first (1.1) in a first stage (I) a carrier is prepared from (Ia) a finely divided silica gel which has a particle diameter of from 1 to 1,000 µm, a pore volume of from 0.3 to 5 cm3/g and a surface area of from 100 to 1,000 m2/g, is of the formula SiO2 . a Al2O3, where a is from 0 to 2, and has a moisture content such that it loses from 1 to 20% by weight, based on the initial total weight of the silica gel, of water at 1000°C in the course of 0.5 hour, (Ib) an organomagnesium compound of the formula MgR3R4, where R3 and R4 are each C2-C10-alkyl, and (Ic) a gaseous chlorinating agent of the formula ClZ, where Z is Cl or H, by a method in which first (1.1.1) in a first sub-stage, in a liquid inert hydro-carbon, with constant thorough mixing at from 10 to 120°C, the finely divided silica gel (Ia) and the organo-magnesium compound (Ib) are combined, from 1 to 10 molar parts of the organomagnesium compound (Ib) being used per 10 molar parts of silicon of the silica gel (Ia), and the combined substances are kept at from 20 to 140°C, for from 0.5 to 5 hours, then (1.1.2) in a second sub-stage, with constant thorough mixing at from -20 to +80°C, the gaseous chlorinating agent (Ic) is passed into the mixture obtained from the first sub-stage, from 2 to 40 molar parts of the chlorinating agent (Ic) being used per molar part of the organomagnesium compound (Ib), the entire mixture is left at a temperature in the stated range for from 0.5 to 5 hours and the resulting solid-phase product, ie. the carrier (I), is isolated with removal of the liquid phase, thereafter (1.2) in a second stage, a solid-phase intermediate is prepared from (I) the carrier obtained in the first stage, (II) a C1-C8-alkanol, (III) titanium tetrachloride and (IV) a phthalic acid derivative of the formula where X and Y together are oxygen or X and Y are each chlorine or C1-C10-alkoxy, by a method in which first (1.2.1) in a first sub-stage, in a liquid inert hydro-carbon, with constant thorough mixing at room tempera-ture, the carrier (I) and the alkanol (II) are combined, from 1 to 5 molar parts of the alkanol (II) being used per molar part of magnesium of the carrier (I), and the combined substances are kept at from 20 to 140°C for from 0.5 to 5 hours, then (1.2.2) in a second sub-stage, with constant thorough mixing at room temperature, the titanium tetrachloride (III) is introduced into the reaction mixture resulting from the first sub-stage, from 2 to 20 molar parts of the titanium tetrachloride (III) being used per molar part of magnesium of the carrier (I), the combined substances are kept at from 10 to 150°C for from 0.5 to 5 hours, and the resulting solid-phase intermediate is isolated with removal of the liquid phase, with the proviso that the phthalic acid derivative (IV) is introduced in the course of one or both of the sub-stages (1.2.1) and (1.2.2), from 0.01 to 1 molar part of the phthalic acid derivative (IV) being used per molar part of magnesium of the carrier (I), then (1.3) in a third stage, the solid-phase intermediate obtained from the second stage is subjected, at from 100 to 150°C, for from 0.2 to 5 hours, to a single-stage, multistage or continuous extraction with titanium tetra-chloride or a mixture of titanium tetrachloride and an alkylbenzene of not more than 12 carbon atoms, which contains not less than 5% by weight of titanium tetra-chloride, a total of from 10 to 1,000 parts by weight of the extracting agent being used per 10 parts by weight of the solid-phase intermediate obtained from the second stage, and finally (1.4) in a fourth stage, the solid-phase product formed in the third stage is washed with a liquid inert hydro-carbon, until the hydrocarbon contains less than 2% by weight of titanium tetrachloride, and the titanium com-ponent (1) is thus obtained, and (.beta.) polymerization is carried out by a method in which (a) in the first polymerization zone, the reaction is carried out under a total pressure of from 20 to 40 bar and at from 60 to 90°C, with the proviso that the mean residence time of the polymer is from 1.5 to 5 hours, (b) in the second polymerization zone, the reaction is carried out under a total pressure of from 7 to 25 bar and at from 40 to 70°C, with the proviso that the ratio of the propylene partial pressure to the ethylene partial pressure is from 100 : 20 to 100 : 120, (c) the total pressure in the first polymerization zone is kept at least 7 bar higher than the total pres-sure in the second polymerization zone, (d) the ratio of the weight of the propylene converted into polymer in the first polymerization zone to the weight of the propylene/ethylene mixture converted into polymer in the second polymerization zone is from 100 : 40 to 100 : 150, and (e) the mean residence time of the polymer in the second polymerization zone is equal to the mean residence time of the polymer in the first polymerization zone multiplied by 0.8-1.2 times the quotient of the amount of polymer discharged hourly from the first polymerization zone to the amount of polymer dis-charged hourly from the second polymerization zone.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE3827565A DE3827565A1 (en) | 1988-08-13 | 1988-08-13 | METHOD FOR PRODUCING PROPYLENE-ETHYLENE POLYMERISATES OF THE TYPE OF THE SOCIAL "IMPACT-MODIFIED POLYPROPYLENE" |
| DEP3827565.1 | 1988-08-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1333828C true CA1333828C (en) | 1995-01-03 |
Family
ID=6360818
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000607986A Expired - Fee Related CA1333828C (en) | 1988-08-13 | 1989-08-10 | Preparation of propylene/ethylene polymers of the toughened polypropylene type |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US4977210A (en) |
| EP (1) | EP0355603B1 (en) |
| JP (1) | JP2768749B2 (en) |
| AT (1) | ATE104685T1 (en) |
| AU (1) | AU606294B2 (en) |
| CA (1) | CA1333828C (en) |
| DE (2) | DE3827565A1 (en) |
| ES (1) | ES2063086T3 (en) |
| IE (1) | IE63798B1 (en) |
| ZA (1) | ZA896141B (en) |
Families Citing this family (24)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2654108B1 (en) * | 1989-11-08 | 1993-08-20 | Norsolor Sa | NOVEL POLYOLEFIN RUBBERS AND THEIR PREPARATION METHOD. |
| DE4019053A1 (en) * | 1990-06-15 | 1991-12-19 | Basf Ag | POLYMERISATES OF PROPYLENE WITH A WIDE MOLECULAR RATIO Q |
| US6300434B1 (en) * | 1991-05-31 | 2001-10-09 | Basell Polyolefin Gmbh | Propylene-ethylene copolymers made from three different constituents |
| DE4119283A1 (en) * | 1991-06-12 | 1992-12-17 | Basf Ag | HIGHLY FLOWABLE MIXTURES FROM DIFFERENT PROPYLENE POLYMERISATS |
| DE4119345A1 (en) * | 1991-06-12 | 1992-12-17 | Basf Ag | PROPYLENE-ETHYLENE-COPOLYMERISATE WITH HIGH RUBBER CONTENT |
| IT1250731B (en) * | 1991-07-31 | 1995-04-21 | Himont Inc | LOW DENSITY LINEAR POLYETHYLENE PREPARATION PROCEDURE |
| JP3162848B2 (en) * | 1991-12-25 | 2001-05-08 | 三井化学株式会社 | Crosslinked polyolefin molded article and method for producing the same |
| US5314746A (en) * | 1992-11-12 | 1994-05-24 | Quantum Chemical Corporation | Soft, puncture- and tear-resistant polyolefin films |
| US5705576A (en) * | 1992-11-12 | 1998-01-06 | Quantum Chemical Corporation | Process for controlling production of in-situ thermoplastic polyolefins and products |
| US5587436A (en) * | 1992-11-12 | 1996-12-24 | Quantum Chemical Corporation | Process for controlling the polymerization of propylene and ethylene and copolymer products |
| DE4317655A1 (en) * | 1993-05-27 | 1994-12-01 | Basf Ag | Multi-phase block copolymers of propylene |
| US6284857B1 (en) | 1993-07-22 | 2001-09-04 | Mitsui Chemical, Inc. | Propylene polymer, propylene block copolymer, process for preparing said polymer and said block copolymer, and propylene polymer composition |
| DE4330661A1 (en) * | 1993-09-10 | 1995-03-16 | Basf Ag | Cold impact propylene polymers |
| DE4415625A1 (en) * | 1994-05-04 | 1995-11-09 | Basf Ag | Copolymers of propylene with a high rubber content |
| KR100341040B1 (en) * | 1994-08-18 | 2002-11-23 | 칫소가부시키가이샤 | High Rigidity Propylene-Ethylene Block Copolymer Composition and Its Manufacturing Method |
| DE4432798A1 (en) * | 1994-09-15 | 1996-03-21 | Basf Ag | Highly flexible propylene-ethylene copolymers |
| JP3275223B2 (en) * | 1994-09-22 | 2002-04-15 | 科学技術振興事業団 | Polypropylene-b-poly (ethylene-co-propylene) and method for producing the same |
| DE19543293A1 (en) | 1995-11-21 | 1997-05-22 | Basf Ag | Copolymers of propylene |
| DE19545498A1 (en) * | 1995-12-06 | 1997-06-12 | Basf Ag | Improved propylene polymers |
| US5861463A (en) * | 1996-10-31 | 1999-01-19 | The Dow Chemical Company | Impact-modified thermoplastic polyolefins and articles fabricated therefrom |
| WO1999026986A1 (en) * | 1997-11-21 | 1999-06-03 | Chisso Petrochemical Corporation | PROCESS FOR THE PREPARATION OF POLYPROPYLENE-b-POLY(ETHYLENE-co-PROPYLENE) |
| DE10025727A1 (en) | 2000-05-25 | 2002-01-03 | Basell Polypropylen Gmbh | Highly flowable propylene block copolymers |
| CN101585924B (en) * | 2009-03-05 | 2012-05-23 | 南京诚盟机械有限公司 | Production line of EPP polypropylene foaming beads |
| CN110437359A (en) * | 2019-07-03 | 2019-11-12 | 联泓新材料科技股份有限公司 | A kind of polyacrylic preparation method of milky tea cup |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL6402946A (en) * | 1963-03-27 | 1964-09-28 | ||
| DE2049622C3 (en) * | 1970-10-09 | 1979-12-13 | Basf Ag, 6700 Ludwigshafen | Process for dissipating heat in the polymerization of monomers in the gas phase |
| US4284738A (en) * | 1980-08-11 | 1981-08-18 | El Paso Polyolefins Company | Ethylene-propylene block copolymerization process and product |
| DE3144312A1 (en) * | 1981-11-07 | 1983-05-19 | Basf Ag, 6700 Ludwigshafen | METHOD FOR THE PRODUCTION OF PROPYLENE-ETHYLENE-POLYMERISATES OF THE TYPE OF THE SOCKET COPOLYMERS |
| DE3214246A1 (en) * | 1982-04-17 | 1983-10-27 | Basf Ag, 6700 Ludwigshafen | METHOD FOR PRODUCING PROPYLENE-ETHYLENE-POLYMERISATES OF THE TYPE OF THE SOCIAL "BLOCK-COPOLYMERISATE" |
| DE3317353A1 (en) * | 1983-05-13 | 1984-11-15 | Basf Ag, 6700 Ludwigshafen | METHOD FOR PRODUCING PROPYLENE-ETHYLENE POLYMERISATES OF THE TYPE OF THE SOCIAL BLOCK COPOLYMERISATE |
| JPS62116618A (en) * | 1985-11-15 | 1987-05-28 | Chisso Corp | Continuous production of propylene/ethylene block copolymer |
| US4882380A (en) * | 1987-07-07 | 1989-11-21 | Union Carbide Chemicals And Plastics Company Inc. | Process for the production of impact polypropylene copolymers |
| DE3730022A1 (en) * | 1987-09-08 | 1989-03-16 | Basf Ag | METHOD FOR PRODUCING HOMO AND COPOLYMERISATS OF PROPEN BY MEANS OF A ZIEGLER-NATTA CATALYST SYSTEM |
| AU599201B2 (en) * | 1988-01-29 | 1990-07-12 | Basf Aktiengesellschaft | Preparation of propylene/ethylene polymers |
-
1988
- 1988-08-13 DE DE3827565A patent/DE3827565A1/en not_active Withdrawn
-
1989
- 1989-08-04 US US07/389,818 patent/US4977210A/en not_active Expired - Lifetime
- 1989-08-10 CA CA000607986A patent/CA1333828C/en not_active Expired - Fee Related
- 1989-08-10 EP EP89114820A patent/EP0355603B1/en not_active Expired - Lifetime
- 1989-08-10 DE DE58907496T patent/DE58907496D1/en not_active Expired - Fee Related
- 1989-08-10 ES ES89114820T patent/ES2063086T3/en not_active Expired - Lifetime
- 1989-08-10 AT AT8989114820T patent/ATE104685T1/en not_active IP Right Cessation
- 1989-08-11 IE IE259789A patent/IE63798B1/en not_active IP Right Cessation
- 1989-08-11 ZA ZA896141A patent/ZA896141B/en unknown
- 1989-08-11 JP JP1207070A patent/JP2768749B2/en not_active Expired - Fee Related
- 1989-08-11 AU AU39510/89A patent/AU606294B2/en not_active Ceased
Also Published As
| Publication number | Publication date |
|---|---|
| EP0355603A3 (en) | 1991-11-27 |
| IE63798B1 (en) | 1995-06-14 |
| DE3827565A1 (en) | 1990-02-15 |
| ZA896141B (en) | 1991-04-24 |
| US4977210A (en) | 1990-12-11 |
| ES2063086T3 (en) | 1995-01-01 |
| EP0355603A2 (en) | 1990-02-28 |
| AU606294B2 (en) | 1991-01-31 |
| ATE104685T1 (en) | 1994-05-15 |
| JPH0288612A (en) | 1990-03-28 |
| AU3951089A (en) | 1990-02-15 |
| DE58907496D1 (en) | 1994-05-26 |
| IE892597L (en) | 1990-02-13 |
| JP2768749B2 (en) | 1998-06-25 |
| EP0355603B1 (en) | 1994-04-20 |
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