WO2025254855A1 - Polymérisation de compositions à base de propylène présentant une réponse améliorée à l'hydrogène et procédés associés - Google Patents
Polymérisation de compositions à base de propylène présentant une réponse améliorée à l'hydrogène et procédés associésInfo
- Publication number
- WO2025254855A1 WO2025254855A1 PCT/US2025/030835 US2025030835W WO2025254855A1 WO 2025254855 A1 WO2025254855 A1 WO 2025254855A1 US 2025030835 W US2025030835 W US 2025030835W WO 2025254855 A1 WO2025254855 A1 WO 2025254855A1
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- WIPO (PCT)
- Prior art keywords
- catalyst system
- polymerization
- carbon atoms
- propylene
- transition metal
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- 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
- C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
- C08F110/04—Monomers containing three or four carbon atoms
- C08F110/06—Propene
Definitions
- the present disclosure relates to polyolefin polymerization, and more particularly to compositions and methods for producing polypropylenes and co-monomers thereof having increased hydrogen response.
- Ziegler-Natta catalysts can suffer from relatively low melt flow capability because they are limited by the concentration of hydrogen achievable during the polymerization process.
- concentration of hydrogen itself is limited by its solubility’ in propylene and co-monomers thereof at the temperature and pressure of the polymerization equipment.
- external catalyst donors used to control polypropylene and co-polymers thereof crystallinity also affect response to hydrogen.
- Hydrogen response influences the molecular weight of the produced polymer, where an increase in hydrogen response produces lower molecular weight polymers and a decrease in hydrogen response produces higher molecular weight polymers. And as molecular weight decreases, so too does the polymers melt flow rate.
- Polypropylene polymers and co-polymers having a low melt flow can limit the compatibility 7 of the polypropylene compositions and co-polymers thereof with various manufacturing techniques (e.g., extrusion and high throughput molding techniques).
- a Ziegler-Natta catalyst system for propylene and co-monomers thereof polymerization that is capable of producing polymers that exhibits a high response to hydrogen and thus is characterized by high melt flow, with substantially undiminished crystallinity' as defined by xylene solubles is desirable.
- a catalyst system for the polymerization of olefin monomers.
- the catalyst system includes a Ziegler-Natta catalyst, a dialkyl diamino silane external donor, and a tetraethyl orthosilicate (TEOS) external donor.
- TEOS tetraethyl orthosilicate
- a method includes introducing a catalyst system into a reactor, the catalyst system including a Ziegler-Natta catalyst, a dialkyd diamino silane external donor, and a tetraethyl orthosilicate (TEOS) external donor, and feeding olefin monomers into the reaction zone under conditions for polymerization, thereby resulting a polyolefin polymers.
- a catalyst system including a Ziegler-Natta catalyst, a dialkyd diamino silane external donor, and a tetraethyl orthosilicate (TEOS) external donor
- FIG. 1 shows a chart of MFR for various concentrations of polymerization results according to the present disclosure compared to comparative polymerization results.
- FIG. 2 shows a chart of %XS for various concentrations of polymerization results according to the present disclosure compared to comparative polymerization results.
- FIG. 3 shows a chart of Activity' for various concentrations of polymerization results according to the present disclosure compared to comparative polymerization results.
- the present disclosure relates to polyolefin polymerization, and more particularly to compositions and methods for producing polypropylenes and co-monomers thereof having increased hydrogen response.
- compositions and methodology for the production of polypropylene compositions and co-monomer compositions thereof having increased melt flow without compromised crystallinity 7 which will be suitable for one or more particular enduses.
- the present disclosure provides a methodology that employs compositional details to permit increased melt flow of polypropylene compositions and co-monomers thereof by utilizing a combination of a Ziegler-Natta catalyst and a combination of two external electron donors: a dialkyl diamino silane and tetraethyl orthosilicate (TEOS).
- TEOS tetraethyl orthosilicate
- the dialkyl diamino silane has the composition of R ⁇ SiiNHR 2 ⁇ , as provided below, and the TEOS is present in an amount of 50% by weight (wt.%) to 90 wt.% of the Ziegler-Natta catalyst system; upon polymerization of olefin monomers, the catalyst system exhibits a level of xylene solubles less than about 3 wt.% and a melt flow rate of greater than 700 grams per gram per hour.
- the combined ratio of the dialkyl diamino silane and TEOS external donors to the titanium (Ti) in the Ziegler-Natta catalyst is in the range of about 8 to 50 molar ratio, encompassing any value and subset therebetween, such as about 10 to 50 molar ratio, or about 20 to 50 molar ratio, or about 30 to 50 molar ratio, or about 40 to 50 molar ratio, or about 50 molar ratio.
- the term “catalyst system,” and grammatical variants thereof, refers to a Ziegler-Natta catalyst in combination with the at least two external donors described herein: a di al ky 1 diamino silane and tetraethyl orthosilicate (TEOS) to effect polymerization of olefins to polyolefins.
- TEOS tetraethyl orthosilicate
- the term “Ziegler-Natta catalyst” may be used interchangeably with simply “catalyst,” and may be comprised of a solid and supported catalyst from titanium and a co-catalyst, usually of aluminum.
- a “polymer,” and grammatical variants thereof, refers to act as stereoselective control agents to control the amount of atactic or non-stereoregular polymer produced during polymerization in the presence of a Ziegler-Natta catalyst.
- a “polymer,” and grammatical variants thereof, is comprised of polymerized olefin monomers, such as polymerized polypropylene homopolymers of propylene monomer (propylene-derived units) or co-monomers of polypropylene and additional olefin monomers, such as ethylene.
- a “reactor,” and grammatical variants thereof, as used herein, is any type of vessel or containment device in any configuration of one or more reactors, and/or one or more reaction zones, wherein a similar polymer is produced; however, two or more reactors that are fluidly connected with one another can each produce separate polymers.
- melt flow rate or “MFR,” and grammatical variants thereof, is the number of grams extruded in 10 minutes under the action of a standard load and is an inverse measure of viscosity.
- a high MFR implies low viscosity and low MFR implies high viscosity.
- polymers are shear thinning, which means that their resistance to flow decreases as the shear rate increases. This is due to molecular alignments in the direction of flow and disentanglements.
- MFR (12, 230°C, 2.16 kg) is determined according to ASTM D-1238-E(20) and is measured in decigrams per minute (dg/min).
- the term “activity,” and grammatical variants thereof, refers to the ability of a catalyst system to increase the rate of a reaction, such as polymerization, and is measured in grams per gram per hour (g/g/hr).
- the term “percent xylene solubles” or “%XS,” and grammatical variants thereof, refers to the percentage of soluble species in a polymer.
- the %XS is measured according to ASDM D5492-17 (2017) and is measured by weight or by CRYSTEX® (approved for xylene solubles determination by ISO 16152) (Polymer Char, Valencia, Spain).
- the %XS is a measure of the crystallinity of a polymer associated with the alignment of its molecular chains, and higher crystallinity may lead to a decrease in MFRs.
- IV is a measure of a solutes’ contribution to the viscosity of a polymer.
- the polymers described herein were tested for IV by the use of a soluble fractional analysis instrument (“SFRA”), using a CRYSTEXTM QC, Polymer Char (Valencia, Spain) instrument. The IV is reported in deciliters per gram (dL/g).
- the Ziegler-Natta catalyst system is designed to increase MFR in response to hydrogen of a polyolefin polymer, such as a polypropylene polymer or co-monomer thereof.
- the catalyst system comprises a Ziegler-Natta catalyst and at least two external donors of a dialkyl diamino silane (e.g, R 1 2Si(NHR 2 )2) and TEOS. It is shown that the inclusion of the dialkyl diamino silane and TEOS as part of the catalyst system improves both MFR in response to hydrogen, particularly at equal or higher concentrations of the combined external donors to the Ziegler-Natta catalyst, without substantially influencing %XS.
- a dialkyl diamino silane e.g, R 1 2Si(NHR 2 )2
- Suitable Ziegler-Natta catalyst components for use as part of the catalyst system of the present disclosure are not considered to be particularly limited. That is, Ziegler-Natta catalyst components in combination with a dialkyl diamino silane and TEOS, as described herein, can increase MFR response to hydrogen of a polyolefin polymer, without substantially influencing %XS, compared to a Ziegler-Natta catalyst system utilizing traditional external donors. Moreover, the MFR response to hydrogen of the present disclosure is improved relative to a dialkyl diamino silane external donor alone or TEOS alone.
- the Ziegler-Natta catalyst components of the present disclosure include a transition metal, or a transition metal halide, compound, in combination with an alkyl aluminum compound.
- the transition metal or transition metal halide may be selected from Group IV -VII (e.g., typically titanium, chromium, vanadium, zirconium, and/or hafnium).
- the alkyl aluminum compound may be an organoaluminumaluminum compound including, but not limited to, a dialkylaluminum (e.g., diethylaluminum chloride); a trialkylaluminum (e.g., triethylaluminum, triisopropylaluminum, tri-n-butylaluminum, tri-n-hexylaluminum, and triisobutylaluminum), an alkylaluminum halide (e.g, diethylaluminum chloride, diethylaluminum bromide, and diethylaluminum hydride). Any combination of the foregoing may be used. Triethylaluminum may be preferred in the compositions and methods of the present disclosure.
- a dialkylaluminum e.g., diethylaluminum chloride
- a trialkylaluminum e.g., triethylaluminum, triisopropy
- suitable Ziegler-Natta catalysts may include, but are not limited to, a mixture of TiCl x , MgCh, or SiCL with Al(Alkyl)3; a mixture of Ti-, Zr-, or Hf-based complexes with methylaluminoxane (MAO); a mixture of titanium tetrachloride (TiCh) with triethylaluminum (Al(C2Hs)3); a mixture of titanium(III) chloride (TiCh) with AlfCdHs)?
- a mixture of TiCl x , MgCh, or SiCL with Al(Alkyl)3 a mixture of Ti-, Zr-, or Hf-based complexes with methylaluminoxane (MAO)
- TiCh titanium tetrachloride
- Al(C2Hs)3 triethylaluminum
- TiCh titanium(III) chloride
- VCU vanadium tetrachloride
- Al ⁇ Hs Cl di ethylaluminum chloride
- a magnesium compound e.g, MgCb
- a titanium compound e.g. an alkoxy titanium, a titanium halide, an alkoxytitanium halide, any combination thereof
- Al(Alkyl)3 or an Al(Alkyl)2 e.g., Al(Alkyl)2(Alkenyl)
- An example of a suitable Ziegler- Natta catalyst includes the catalyst provided in U.S. Patent Publication No.
- dialkyl diamino silane external donors of the present disclosure of the present disclosure are not considered to be particularly limited, provided they are compatible with the selected Ziegler-Natta catalyst and TEOS.
- the dialkyl diamino silanes for use as an external donor (in combination with TEOS) for polymerization of a polyolefin monomer as described herein may have the formula:
- R 1 2 Si(NHR 2 ) 2 where R 1 is a linear, branched, or cyclic alkyl group having between 3 and 6 carbon atoms, encompassing any value and subset therebetween; and R 2 is a linear, branched, or cyclic alkyl group having between 1 and 6 carbon atoms, encompassing any value and subset therebetween.
- the dialkyl diamino silane may have the composition of: R 1 2Si(NHR 2 )2.
- R 1 is a cyclic alkyl having 4 carbon atoms, 5 carbon atoms, or 6 carbon atoms, or between 4 and 6 carbon atoms.
- R 2 is a linear alkyl having 1 to 6 carbon atoms.
- R 1 is a cyclic alkyl having 4 carbon atoms, 5 carbon atoms, or 6 carbon atoms; and R 2 is a linear alkyd having 1 to 6 carbon atoms.
- the catalyst system of the present disclosure may further comprise an internal (electron) donor to modify the surface of a Ziegler-Natta catalyst.
- Suitable examples of internal donors may include, but are not limited to an alkyl benzoate, a phthalate, a succinate, a diether, and any combination thereof.
- Polymerization of olefins using the Ziegler-Natta catalyst is influenced by the inclusion of the combination of external donors of a dialkyl diamino silane and TEOS, as described herein.
- the Ziegler-Natta catalyst system comprises at least an external donor of a dialkyl diamino silane and TEOS.
- the dialkyl diamino silane external donor comprises the above-described composition of R ⁇ SifNHR 2 ⁇ .
- the Ziegler-Natta catalyst component is coupled with the external donor combination of a dialkyl diamino silane and TEOS in an amount in which TEOS is present in an amount of about 45 wt.% to about 95 wt.% of the dialkyl diamino silane, or about 50 wt.% t or about 90 wt.%, or about 50 wt.% to about 80 wt.%, or about 45 wt.% to about 70 wt%, or about 60 wt.% to about 70 wt.%, or about 70 wt.% to about 80 wt.%, or about 80 wt.% to about 95 wt.%, encompassing any value and subset therebetween.
- TEOS is well known as a poor external donor alone, but when in combination with the dialkyl diamino silane external donors of the present disclosure, even at high concentrations of TEOS, the external donor activity is greatly improved.
- the resultant olefin polymers polymerized in the presence of the catalyst system described herein comprise a xylene soluble component composing less than about 5 wt.%. such as in the range of about 0. 1 wt.% to about 5 wt.%, or about 0.5 wt.% to about 3 wt.%, or about 1 wt.% to about 3 wt.%, or about 2 wt.% to about 3 wt.%, or about 0.5 wt.% to about 1 wt.%, or about 1 wt.% to about 2 wt.%, encompassing any value and subset therebetween.
- the resultant olefin polymers polymerized in the presence of the catalyst system described herein demonstrate an increased MFR response to hydrogen.
- the MFR will depend on solubility limitations, which include the type of equipment used (e.g., plant equipment that is liquid-full v. lab equipment having a head space) and the hydrogen concentration in propylene.
- solubility limitations include the type of equipment used (e.g., plant equipment that is liquid-full v. lab equipment having a head space) and the hydrogen concentration in propylene.
- the aforementioned MRF values are based on the definition provided above.
- the resultant olefin polymers polymerized in the presence of the catalyst system described herein exhibit good activity as would be recognized by one of skill in the art, such as greater than 25,000 g/g/hr, such as in the range of about 25,000 g/g/hr to about 140,000 g/g/hr. or about 30,000 g/g/hr to about 60,000 g/g/hr, or about 40,000 g/g/hr to about 60,000 g/g/hr. encompassing any value and subset therebetween.
- Polymerization is performed using certain reaction conditions, such as temperature, pressure, and reaction time suitable for the polymerization of the propylene monomers and any other selected olefin monomers for production of a polypropylene polymer or polypropylene co-polymer, respectively.
- Suitable monomers, in addition to propylene include, but are not limited to, ethylene, 1-butene, 1-pentene, 4-methyl-l -pentene, vinylcyclohexane, and any combination thereof.
- Preferred olefm monomers include propylene alone, propylene in combination with ethylene, and propylene in combination with 1-butene.
- Polymerization is carried out in a reaction zone of one or more reactors, such as a gas phase reactor or other reactor suitable for polymerization. While reaction conditions may vary' depending on a number of factors, such as the particular olefin monomer selections, the following conditions are suitable.
- the polymerization temperatures are preferably about 200°C or lower, and more preferably about 100°C or lower, such as in the range of about 50°C to about 200°C, or about 70°C to about 100°C, encompassing any value and subset therebetween.
- the polymerization pressure is preferably about 10 MPa or less, and more preferably about 5 MPa or less, such as in the range of about 1 MPa to about 10 MPa, or about 1 MPa to about 5 MPa, encompassing any value and subset therebetween.
- the polymerization time, or the residence time during polymerization is normally about 1 minute to about 5 hours, encompassing any value and subset therebetween.
- Examples of the polymerization method include a slurry polymerization method in which a solvent of an inert hydrocarbon compound such as cyclohexane and heptane is used, a bulk polymerization method in which a solvent such as liquefied propylene is used, and a gas phase polymerization method in which a solvent is substantially not used.
- Nonlimiting example embodiments of the present disclosure include:
- Embodiment A A catalyst system for the polymerization of olefm monomers comprising: a Ziegler-Natta catalyst; a dialkyl diamino silane external donor; and a tetraethyl orthosilicate (TEOS) external donor.
- a Ziegler-Natta catalyst comprising: a Ziegler-Natta catalyst; a dialkyl diamino silane external donor; and a tetraethyl orthosilicate (TEOS) external donor.
- TEOS tetraethyl orthosilicate
- Embodiment B A method comprising: introducing a catalyst system into a reactor, the catalyst system comprising: a Ziegler-Natta catalyst; a dialkyl diamino silane external donor, and a tetraethyl orthosilicate (TEOS) external donor; and feeding olefm monomers into the reaction zone under conditions for polymerization, thereby resulting a polyolefin polymers.
- a catalyst system comprising: introducing a catalyst system into a reactor, the catalyst system comprising: a Ziegler-Natta catalyst; a dialkyl diamino silane external donor, and a tetraethyl orthosilicate (TEOS) external donor; and feeding olefm monomers into the reaction zone under conditions for polymerization, thereby resulting a polyolefin polymers.
- TEOS tetraethyl orthosilicate
- Nonlimiting example embodiments A and B may include one or more of the following elements:
- Element 1 wherein the dialkyl diamino silane is represented by the formula R 1 2Si(NHR 2 )2, where R 1 is a linear, branched, or cyclic alkyl group having between 3 and 6 carbon atoms and R 2 is a linear, branched, or cyclic alkyl group having between 1 and 6 carbon atoms.
- Element 2 Wherein the dialkyl diamino silane is represented by the formula R 1 2Si(NEIR 2 )2, where R 1 is a cyclic alkyl group having 4 carbon atoms and R 2 is a linear, branched, or cyclic alkyl group having between 1 and 6 carbon atoms.
- Element 3 Wherein the dialkyl diamino silane is represented by the formula R 1 2Si(NEIR 2 )2, where R 1 is a cyclic alk l group having 5 carbon atoms and R 2 is a linear, branched, or cy devis alky l group having between 1 and 6 carbon atoms.
- Element 4 Wherein the dialkyl diamino silane is represented by the formula R 1 2Si(NHR 2 )2. where R 1 is a cyclic alkyl group having 6 carbon atoms and R 2 is a linear, branched, or cyclic alkyl group having between 1 and 6 carbon atoms.
- Element 5 Wherein the dialkyl diamino silane is represented by the formula R’2Si(NHR 2 )2, where R 1 is a linear, branched, or cyclic alkyl group having between 3 and 6 carbon atoms and R 2 is a linear alkyl group having between 1 and 6 carbon atoms.
- Element 6 Wherein the catalyst system comprises a transition metal compound and an alkyl aluminum compound.
- Element 7 Wherein the catalyst system comprises a transition metal compound and an alkyl aluminum compound, and wherein the transition metal is a transition metal halide.
- Element 8 Wherein the catalyst system comprises a transition metal compound and an alkyl aluminum compound, and wherein the alkylaluminum compound is a dialkylaluminum or a tri alk laluminum.
- Nonlimiting combinations applicable to embodiments A and B include: 1, 2, and/or 5-8; 1 3, and/or 5-8; 1 and/or 5-8; 2 and/or 5-8; 3 and/or 5-8; 4 and/or 5-8; and any combination of 5-8, without limitation.
- Nonlimiting example embodiment B may include one or more of the following elements: [0057] Element 9: Wherein the olefin monomers are selected from the group consisting of propylene, ethylene, 1-butene, 1-pentene, 4-methyl-l -pentene, vinylcyclohexane. and any combination thereof.
- Element 10 Wherein the olefin monomers are propylene.
- Element 11 Wherein the olefin monomers are propylene and ethylene.
- Element 12 Wherein the polyolefin polymers have a xylene solubles value of less than about 3%.
- Element 13 Wherein the polyolefin polymers have a xylene solubles value in the range of about 0.5% to about 3%.
- Nonlimiting combinations applicable to embodiment B include: 9 and 12; 9 and 13; 10 and 12; 10 and 13; 11 and 12; 11 and 13, without limitation.
- the combination of dialkyl diamino silane and TEOS show an increase in MFR response to hydrogen. Moreover, the greater the TEOS concentration in the catalyst system (despite being known as a poor external donor), the greater the MFR and. thus, the hydrogen response. Moreover, the addition of DAS1 and TEOS does not substantially influence the %XS at concentrations of less than about 95% TEOS, indicating that cry stallinity has not substantially changed. Comparative PTES samples show' generally higher %XS and substantially no change in MFR. Accordingly, the addition of a combination of external donors of a dialkyl diamino silane and TEOS to a Ziegler-Natta catalyst component can substantially increase hydrogen response and MFR. The results are visually provided in FIGS. 1-3.
- compositions described herein may be free of any component, or composition not expressly recited or disclosed herein. Any method may lack any step not recited or disclosed herein.
- composition, element, or elements are considered synonymous with the term “including.”
- transitional phrase “comprising” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa.
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Abstract
L'invention concerne un système de polymérisation d'oléfine pour augmenter la réponse d'écoulement à l'état fondu à l'hydrogène de polymères polyoléfiniques résultants. Le système catalyseur pour la polymérisation de monomères oléfiniques comprend un catalyseur Ziegler-Natta en combinaison avec deux donneurs externes d'un dialkyldiamino silane et d'orthosilicate de tétraéthyle.
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| Application Number | Priority Date | Filing Date | Title |
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| US202463656688P | 2024-06-06 | 2024-06-06 | |
| US63/656,688 | 2024-06-06 |
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| WO2025254855A1 true WO2025254855A1 (fr) | 2025-12-11 |
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| PCT/US2025/030835 Pending WO2025254855A1 (fr) | 2024-06-06 | 2025-05-23 | Polymérisation de compositions à base de propylène présentant une réponse améliorée à l'hydrogène et procédés associés |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7183234B2 (en) * | 2004-04-29 | 2007-02-27 | Exxonmobil Chemical Patents Inc. | Multi-donor catalyst system for the polymerization of olefins |
| US20120004378A1 (en) * | 2009-03-17 | 2012-01-05 | Toho Titanium Co., Ltd | Solid catalyst component and catalyst for polymerization of olefins, and process for production of olefin polymers using same |
| US9206273B2 (en) * | 2013-02-27 | 2015-12-08 | Toho Titanium Co., Ltd. | Solid catalyst component for polymerizing olefins, catalyst for polymerizing olefins, and production method for polymerized olefins |
| WO2022015627A2 (fr) | 2020-07-17 | 2022-01-20 | Exxonmobil Chemical Patents Inc. | Polymères à faibles niveaux de composés organiques volatils et procédés de fabrication de tels polymères |
-
2025
- 2025-05-23 WO PCT/US2025/030835 patent/WO2025254855A1/fr active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7183234B2 (en) * | 2004-04-29 | 2007-02-27 | Exxonmobil Chemical Patents Inc. | Multi-donor catalyst system for the polymerization of olefins |
| US20120004378A1 (en) * | 2009-03-17 | 2012-01-05 | Toho Titanium Co., Ltd | Solid catalyst component and catalyst for polymerization of olefins, and process for production of olefin polymers using same |
| US9206273B2 (en) * | 2013-02-27 | 2015-12-08 | Toho Titanium Co., Ltd. | Solid catalyst component for polymerizing olefins, catalyst for polymerizing olefins, and production method for polymerized olefins |
| WO2022015627A2 (fr) | 2020-07-17 | 2022-01-20 | Exxonmobil Chemical Patents Inc. | Polymères à faibles niveaux de composés organiques volatils et procédés de fabrication de tels polymères |
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