Ziegler-natta catalyst for polyolefins

Abstract

A Ziegler-Natta type catalyst component can be produced by a process comprising contacting a magnesium dialkoxide compound with a halogenating agent to form a reaction product A, and contacting reaction product A with a first, second and third halogenating/titanating agents. Catalyst components, catalysts, catalyst systems, polyolefin, products made therewith, and methods of forming each are disclosed. The reaction products can be washed with a hydrocarbon solvent to reduce titanium species [Ti] content to less than about 100 mmol/L.

1 . A catalyst produced by a process comprising: 
 a) contacting a catalyst component with an organometallic preactivating agent, wherein the catalyst component is produced by a process comprising, 
 i) contacting a magnesium dialkoxide compound with a halogenating agent to form a reaction product A;  
 ii) contacting reaction product A with a first halogenating/titanating agent to form reaction product B;  
 iii) contacting reaction product B with a second halogenating/titanating agent to form reaction product C; and  
 iv) contacting reaction product C with a third halogenating/titanating agent to form a catalyst component.  
   
     
     
         2 . The catalyst of  claim 1  wherein the organometallic preactivating agent is an aluminum alkyl of the formula AIR 3  wherein at least one R is an alkyl having 1-8 carbon atoms or a halide, and wherein each R may be the same or different.  
     
     
         3 . The catalyst of  claim 2  wherein the organometallic preactivating agent is a trialkyl aluminum.  
     
     
         4 . The catalyst of  claim 3  wherein the second and third halogenating/titanating agents comprise titanium tetrachloride.  
     
     
         5 . The catalyst of  claim 4  wherein the ratio of aluminum to titanium is in the range from 0.1:1 to 2:1.  
     
     
         6 . The process of  claim 1  wherein reaction products A, B, and C are washed with a hydrocarbon solvent prior to subsequent halogenating/titanating steps.  
     
     
         7 . The process of  claim 1  wherein the catalyst component is washed with a hydrocarbon solvent until titanium species [Ti] content is less than about 20 mmol/L.  
     
     
         8 . A polymer produced by a process comprising: 
 a) contacting one or more olefin monomers together in the presence of a catalyst under polymerization conditions,    wherein the catalyst is produced by a process comprising 
 i) contacting a magnesium dialkoxide compound with a halogenating agent to form a reaction product A;  
 ii) contacting reaction product A with a first halogenating/titanating agent to form reaction product B;  
 iii) contacting reaction product B with a second halogenating/titanating agent to form reaction product C;  
 iv) contacting reaction product C with a third halogenating/titanating agent to form a catalyst component; and  
 b) extracting polyolefin polymer.  
   
     
     
         9 . The polymer of  claim 8  wherein the catalyst is produced by a process further comprising: 
 v) contacting the catalyst component with an organoaluminum agent.    
     
     
         10 . The polymer of  claim 8  wherein the second and third halogenating/titanating agents comprise titanium tetrachloride.  
     
     
         11 . The polymer of  claim 8  wherein reaction products A, B, and C are washed with a hydrocarbon solvent prior to subsequent halogenating/titanating steps.  
     
     
         12 . Film, fiber, pipe, textile material, or an article of manufacture comprising the polymer of  claim 8 .  
     
     
         13 . A process for olefin polymerization, comprising: 
 a) contacting one or more olefin monomers together in the presence of a catalyst under polymerization conditions, wherein the catalyst was produced by a process comprising: 
 i) contacting a magnesium dialkoxide compound with a halogenating agent to form a reaction product A;  
 ii) contacting reaction product A with a first halogenating/titanating agent to form reaction product B;  
 iii) contacting reaction product B with a second halogenating/titanating agent to form reaction product C;  
 iv) contacting reaction product C with a third halogenating/titanating agent to form a catalyst component to form reaction product D;  
   b) extracting a polyolefin polymer;    wherein at least one reaction product A, B, and C are washed with a hydrocarbon solvent prior to subsequent halogenating/titanating steps; and    wherein the reaction product D is washed with a hydrocarbon solvent until titanium species [Ti] content is less than about 100 mmol/L.    
     
     
         14 . The process of  claim 13  wherein the polymer has a molecular weight distribution of at least 4.0.  
     
     
         15 . The process of  claim 13  wherein the polymer has a bulk density of at least 0.31 g/cc.  
     
     
         16 . An article comprising polymer produced by the process of  claim 13.