Catalyst system, olefin polymerization catalyst components comprising at least an internal electron donor compound, and methods of making and using the same
View Patent ↗An olefin polymerization catalyst component comprising an internal electron donor compound shown in formula (I) below is provided in this disclosure: wherein X is O, S, NR a , PR b , or POOR c , R a is independently hydrogen, halogen, carbonyl hydrocarbon, linear or branched unsaturated or saturated alkyl hydrocarbon, cyclic, aromatic, or aliphatic hydrocarbon, R b is independently hydrogen, halogen, carbonyl hydrocarbon, linear or branched unsaturated or saturated alkyl hydrocarbon, linear or branched unsaturated or saturated alkoxy hydrocarbon, cyclic, aromatic, or aliphatic hydrocarbon, R c is independently hydrogen, carbonyl hydrocarbon, linear or branched unsaturated or saturated alkyl hydrocarbon, cyclic, aromatic, or aliphatic hydrocarbon, R1-R8 are identical or different hydrogen, halogen, linear or branched unsaturated or saturated C 1 -C 30 alkyl, alone or in combination with C 5 -C 30 substituted or unsubstituted 5-or 6-membered aliphatic or aromatic hydrocarbon rings, each of R a , R b , R c , and/or R1-R8 are optionally substituted with halogen.
1. An olefin polymerization catalyst component comprising an internal electron donor compound represented by formula (I):
wherein:
X is O, S, NR a , PR b , or POOR c ,
R a is hydrogen, halogen, a carbonyl hydrocarbon, a linear or branched unsaturated or saturated alkyl hydrocarbon, or an unsubstituted or halogen-substituted moiety selected from the group consisting of a cyclic, an aromatic, and an aliphatic hydrocarbon,
R b is hydrogen, halogen, a carbonyl hydrocarbon, a linear or branched unsaturated or saturated alkyl hydrocarbon, a linear or branched unsaturated or saturated alkoxy hydrocarbon, or an unsubstituted or halogen-substituted moiety selected from the group consisting of a cyclic, an aromatic, and an aliphatic hydrocarbon,
R c is hydrogen, a carbonyl hydrocarbon, a linear or branched unsaturated or saturated alkyl hydrocarbon, or an unsubstituted or halogen-substituted moiety selected from the group consisting of a cyclic, an aromatic, and an aliphatic hydrocarbon, and
R1-R8 are identical or different and are hydrogen, halogen, a linear or branched unsaturated or saturated C1-C30 alkyl, or an unsubstituted or halogen-substituted moiety selected from the group consisting of C5-C30 substituted or unsubstituted 5-or 6-membered aliphatic and aromatic hydrocarbon rings.
2. The olefin polymerization catalyst component of claim 1 , wherein R1 and R2 and/or R7 and R8 form a 5-or 6-membered aliphatic or aromatic hydrocarbon ring optionally substituted with halogen; and R3 is linear or branched unsaturated or saturated C 1 -C 12 alkyl or R3 is linear or branched C 1 -C 12 alkoxy.
3. The olefin polymerization catalyst component of claim 1 , wherein X is O.
4. The olefin polymerization catalyst component of claim 1 , wherein the internal electron donor compound is (D-1) shown below
5. A catalyst system for polymerization of an olefin comprising:
a) the olefin polymerization catalyst component of claim 1 further comprising a titanium halide and/or a magnesium halide;
b) an organoaluminum compound; and
c) optionally an external electron donor.
6. The catalyst system of claim 5 , wherein the magnesium halide is magnesium chloride and the titanium halide is TiCl 4 or TiCl 3 .
7. The catalyst system of claim 5 , wherein the organoaluminum compound is an alkyl-aluminum compound.
8. The catalyst system of claim 7 , wherein the alkyl-aluminum compound is a trialkyl aluminum compound.
9. The catalyst system of claim 8 , wherein the trialkyl aluminum compound is selected from the group consisting of triethylaluminum, triisobutylaluminum, and tri-n-octylaluminum, and combinations thereof.
10. The catalyst system of claim 5 further comprising esters, phthalate compounds, ketones, and/or ethers.
11. A process for polymerizing or copolymerizing an olefin, the process comprising
(a) providing a catalyst system of claim 5 ;
(b) polymerizing or copolymerizing the olefin in a presence of the catalyst system to form a polymer or a copolymer; and
(c) recovering the polymer or the copolymer.
12. The process of claim 11 , wherein the olefin is selected from the group consisting of ethylene, propylene, 1-butylene, 4-methyl-1-pentente, 1-hexene, 1-octene, and mixtures thereof.
13. A catalyst system for polymerization of an olefin, the catalyst system comprising a catalyst component comprising an internal electron donor compound represented by formula (I):
wherein:
X is O, S, NR a , PR b , or POOR c ,
R a is hydrogen, halogen, a carbonyl hydrocarbon, a linear or branched unsaturated or saturated alkyl hydrocarbon, or an unsubstituted or halogen-substituted moiety selected from the group consisting of a cyclic, an aromatic, and an aliphatic hydrocarbon,
R b is hydrogen, halogen, a carbonyl hydrocarbon, a linear or branched unsaturated or saturated alkyl hydrocarbon, a linear or branched unsaturated or saturated alkoxy hydrocarbon, or an unsubstituted or halogen-substituted moiety selected from the group consisting of a cyclic, an aromatic, and an aliphatic hydrocarbon,
R c is hydrogen, a carbonyl hydrocarbon, a linear or branched unsaturated or saturated alkyl hydrocarbon, or an unsubstituted or halogen-substituted moiety selected from the group consisting of a cyclic, an aromatic, and an aliphatic hydrocarbon, and
R1-R8 are identical or different and are hydrogen, halogen, a linear or branched unsaturated or saturated C1-C30 alkyl, or an unsubstituted or halogen-substituted moiety selected from the group consisting of C5-C30 substituted or unsubstituted 5-or 6-membered aliphatic and aromatic hydrocarbon rings.
14. The catalyst system of claim 13 , wherein X is O;
R1 and R2 and/or R7 and R8 form a 5-or 6-membered hydrocarbon ring optionally substituted with halogen; and
R3 is linear or branched unsaturated or saturated C 1 -C 12 alkyl or R3 is linear or branched C 1 -C 12 alkoxy.
15. A catalyst system for use in olefinic polymerization, the catalyst system comprising:
the olefin polymerization catalyst component of claim 1 ;
an organoaluminum compound; and
an organosilicon compound.
16. The catalyst system of claim 15 , wherein the organoaluminum compound is an alkyl-aluminum compound.
17. The catalyst system of claim 16 , wherein the alkyl-aluminum compound is a trialkyl aluminum compound.
18. The catalyst system of claim 17 , wherein the trialkyl aluminum compound is selected from the group consisting of triethylaluminum, triisobutylaluminum, and tri-n-octylaluminum, and combinations thereof.
19. The catalyst system of claim 15 , wherein the organosilicon compound is represented by chemical formula (II):
R n Si(OR′) 4-n (II)
wherein each R and R′ independently represent a hydrocarbon group, and n is an integer from 0 to 3.
20. The catalyst system of claim 15 , wherein the organosilicon compound is represented by chemical formula (III):
SiRR′ m (OR″) 3-m (III)
wherein R represents a cyclic hydrocarbon or substituted cyclic hydrocarbon group, wherein each R′ and R″ independently represent a hydrocarbon group, and wherein m is an integer from 0 to 2.
21. A process of polymerizing or copolymerizing an olefin monomer, the process comprising:
(i) providing the catalyst system of claim 15 ;
(ii) polymerizing or copolymerizing the olefin monomer in the presence of the catalyst system to form a polymer or a copolymer; and
(iii) recovering the polymer or the copolymer.
22. The process of claim 21 , wherein the olefin monomer is selected from the group consisting of ethylene, propylene, 1-butylene, 4-methyl-1-pentene, 1-hexane, 1-octene, and combinations thereof.