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Process for the in situ blending of polymers
| Details |
Inventors: Lee, Kiu H.; Karol, Frederick J.; Samuels, Sari B.;
Assignee: Union Carbide Chemicals & Plastics Technology Corporation (Danbury, CT)
Primary Examiner: Seccuro; Carman J.
Assistant Examiner:
Attorney, Agent or Firm: Bresch; Saul R.
A process for the in situ blending of polymers comprising continuously contacting, under polymerization conditions, a mixture of ethylene and at least one alpha-olefin having at least 3 carbon atoms with a catalyst in at least two fluidized bed reactors connected in series, said catalyst comprising: (i) a complex consisting essentially of magnesium titanium, a halogen, and an electron donor; (ii) at least one activator compound; and (iii) a hydrocarbyl aluminum cocatalyst, the polymerization conditions being such that ethylene copolymer having a high melt index in the range of about 0.1 to about 1000 grams per 10 minutes is formed in at least one reactor and ethylene copolymer having a low melt index in the range of about 0.001 to about 1.0 gram per 10 minutes is formed in at least one other reactor, each copolymer having a density of about 0.860 to about 0.965 gram per cubic centimeter and a melt flow ratio in the range of about 22 to about 70, and being admixed with active catalyst. |
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DETAILED DESCRIPTION The titanium based complex is exemplified by a complex having the formula Mg.
sub.
a Ti(OR).
sub.
b X.
sub.
c (ED).
sub.
d wherein R is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms or COR' wherein R' is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms; each OR group is alike or different; X is Cl, Br, or I, or mixtures thereof; ED is an electron donor, which is a liquid Lewis base in which the precursors of the titanium based complex are soluble; a is 0.
5 to 56; b is 0, 1, or 2; c is 2 to 116; and d is 2 to 85.
This complex and a method for its preparation are disclosed in U.
S.
Pat.
No.
4,303,771, issued on Dec.
1, 1981 which is incorporated by reference herein.
The titanium compound, which can be used in the above preparations, has the formula Ti(OR).
sub.
a X.
sub.
b wherein R and X are as defined for component (i) above; a is 0, 1 or 2; b is 1 to 4; and a+b is 3 or 4.
Suitable compounds are TiCl.
sub.
3, TiCl.
sub.
4, Ti(OC.
sub.
6 H.
sub.
5)Cl.
sub.
3, Ti(OCOCH.
sub.
3)Cl.
sub.
3 and Ti(OCOC.
sub.
6 H.
sub.
5)Cl.
sub.
3.
The magnesium compound has the formula MgX.
sub.
2 wherein X is as defined for component (i) above.
Suitable examples are MgCl.
sub.
2, MgBr.
sub.
2, and MgI.
sub.
2.
Anhydrous MgCl.
sub.
2 is a preferred compound.
About 0.
5 to 56, and preferably about 1 to 10, moles of the magnesium compound are used per mole of titanium compound.
The electron donor used in the catalyst composition is an organic compound, liquid at temperatures in the range of about 0.
degree.
C.
to about 200.
degree.
C.
It is also known as a Lewis base.
The titanium and magnesium compounds are both soluble in the electron donor.
Electron donors can be selected from the group consisting of alkyl esters of aliphatic and aromatic carboxylic acids, aliphatic ketones, aliphatic amines, aliphatic alcohols, alkyl and cycloalkyl ethers, and mixtures thereof, each electron donor having 2 to 20 carbon atoms.
Among these electron donors, the preferred are alkyl and cycloalkyl ethers having 2 to 20 carbon atoms; dialkyl, diaryl, and alkyaryl ketones having 3 to 20 carbon atoms; and alkyl, alkoxy, and alkylalkoxy esters of alkyl and aryl carboxylic acids having 2 to 20 carbon atoms
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