Ziegler-natta catalyst for high temperature polymerization

Abstract

The various embodiments of the invention provide, a magnesium titanium polymerization procatalyst, methods for making and using the same.

1 - 30 . (canceled) 
     
     
         31 . An olefin polymerization product prepared by the process comprising
 i) adding to one or more continuous stirred tank reactor (CSTR), optionally followed by a tubular reactor, either in series or parallel, a solvent selected from C 5-12  alkanes, or mixtures thereof, and a procatalyst for polymerization on a delta form MgCl 2  support comprising a Ti 3+  complex of the formula TiCl 3 *[[R 4 ] a [R 5 O] b AlX 3-c ]d   
       wherein
 a is 0 to 1; 
 b is 0 to 1; 
 c=a+b; 
 d is from 0.33 to 1.0; 
 each R 4  and R 5  is independently selected from C 1-8  alkyl radicals; 
 each X is independently selected from the halogen radicals; 
 wherein at least 60% of the total Ti present is in the Ti 3+  oxidation state; 
 ii) adding ethylene, hydrogen and optionally one or more comonomers selected from C 3-8  comonomers to the reactor; and 
 iii) adding an aluminum alkyl activator to the reactor in a molar ratio of about 1 to about 10 relative to the amount of procatalyst; and 
 having a density from about 0.912 to about 0.918, and CDBI range of about 50 or more and a MWD of about 3 or less. 
 
     
     
         32 . The olefin polymerization product of  claim 31  that provides less than about 10 ppm calculated residual titanium in the resulting polymer. 
     
     
         33 . The olefin polymerization product of  claim 31  that provides less than about 120 ppm calculated residual halogen in the resulting polymer. 
     
     
         34 . A plastic article selected from films, fibers, molded or thermoformed articles, and pipe coatings comprising an olefin polymerization product of  claim 31 . 
     
     
         35 - 37 . (canceled) 
     
     
         38 . The olefin polymerization product of  claim 31 , wherein the activator is an aluminum alkyl activator selected from diethylaluminumethoxide and trialkyl aluminum compounds, and MAO. 
     
     
         39 . The olefin polymerization product  claim 31 , wherein the solvent is isohexane or decane. 
     
     
         40 . The olefin polymerization product  claim 31 , wherein the polymerization temperature is at least about 240° C. 
     
     
         41 . The olefin polymerization product  claim 31 , wherein the polymerization results in a polymer having the same density but where the process uses at least about 10% less comonomer feed compared to a polymerization process using a procatalyst for polymerization that contains substantially no tetrahedral Ti3+ species. 
     
     
         42 . The olefin polymerization product  claim 31 , wherein the polymerization results in a polymer with the same density but with a higher Mw at any polymerization temperature than the Mw obtained for a polymer prepared using a procatalyst for polymerization that contains substantially no tetrahedral Ti3+ species. 
     
     
         43 . The olefin polymerization product  claim 31 , wherein the reactor hold-up time is from about 30 seconds to about 5 minutes. 
     
     
         44 . The olefin polymerization product  claim 31 , wherein the EPR spectrum and its simulation of the procatalyst for polymerization has a characteristic g value of 1.950. 
     
     
         45 . The olefin polymerization product  claim 31 , wherein electron paramagnetic resonance (EPR) of the procatalyst for polymerization indicates the presence of a species C, wherein the species C is associated with a tetrahedral Ti 3+  species and wherein species C is about 0.2% or more of the Ti 3+  species detected in the EPR spectra. 
     
     
         46 . The olefin polymerization product  claim 31 , wherein electron paramagnetic resonance (EPR) of the procatalyst for polymerization indicates the presence of a species C, wherein the species C is associated with a tetrahedral Ti 3+  species and wherein species C is about 0.3% to about 1% of the Ti 3+  species detected in the EPR spectra.