Process for the polymerization of alpha olefins

Abstract

A process for the stereoregular polymerization of alpha olefins which comprises polymerizing an alpha olefin having from 2 to 8 carbon atoms in the presence of a catalyst comprising: (a) a solid supported titanium tetrahalide complex, wherein said complex is prepared by contacting a mechanically pulverized solid support with titanium tetrahalide in the absence of mechanical pulverization, and (b) a cocatalyst comprising a mixture of a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a process for the stereoregular polymerization of alpha olefins. More particularly, the present invention relates to the polymerization of alpha olefins using a catalyst system comprising a titanium-containing component and a second component comprising a mixture of a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound.

It is known in the art that extremely reactive Ziegler-type catalysts can be prepared by reacting titanium tetrachloride with ethanol in the presence of a pulverized solid support, such as magnesium chloride. Frequently, esters of aromatic carboxylic acids are included in this preparation. The resulting solid complex is then mixed with a trialkyl aluminum compound, such as tri-isobutyl aluminum, to produce the final catalyst. When used to polymerize alpha olefins, these catalysts provide high yields of stereoregular polymer per part of catalyst. As a result, the catalyst normally does not have to be separated from the polymer to give a final polymer product of specification purity.

Accordingly, U.S. Pat. No. 4,143,223 describes a polymerization process using a catalyst composition comprising a mechanically pulverized solid halogen-containing titanium catalyst component and an organoaluminum compound. The titanium catalyst component is obtained by reacting a titanium compound, such as titanium tetrachloride, with a pulverized solid product derived from a magnesium compound, an organic acid ester and an active hydrogen-containing compound selected from alcohols and phenols.

U.S. Pat. No. 4,107,415 describes a polymerization process using a catalyst system comprising a catalyst-forming component which is an addition and/or substitution product of an electron-donor compound (or Lewis base) and an alkyl aluminum compound, and a supported catalyst-forming component obtained by contacting a titanium compound with a carrier which is a mixture of an active magnesium or manganese dihalide and a solid organic material which is inert to all other catalyst components. The electron-donor compound is typically an organic acid ester and the inert solid organic material is a compound such as durene, anthracene, acenaphthene or diphenyl.

Chemical Abstracts, 96:69614c (1982) describes a polymerization catalyst comprising an organic aluminum compound, such as triethyl aluminum, and a solid component obtained by reacting milled mixtures of magnesium dichloride, aromatic carboxylic acid esters and silicon tetrachloride with titanium tetrahalide in the presence of chlorinated hydrocarbons, such as dichloroethane.

SUMMARY OF THE INVENTION

The present invention provides an improved process for the stereoregular polymerization of alpha olefins which comprises polymerizing an alpha olefin having 2 to 8 carbon atoms in the presence of a catalyst comprising (a) a solid supported titanium tetrahalide complex, wherein said complex is prepared by contacting a mechanically pulverized solid support with titanium tetrahalide in the absence of mechanical pulverization, and (b) a cocatalyst comprising a mixture of a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound.

Among other factors, the present invention is based on my discovery that a mixed metal alkyl catalyst containing both a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound is extremely effective in polymerizing alpha olefins to provide highly stereoregular alpha olefin polymers in improved yield. This is particularly surprising in view of the fact that alkyl aluminum halides, which are known to form active Ziegler catalysts, by themselves do not provide effective olefin polymerization catalysts when mixed with solid supported titanium complexes. Similarly, dialkyl magnesium or alkyl lithium compounds by themselves do not produce good polymerization catalysts when mixed with titanium complexes.

Equally surprising, in view of the prior art teaching, is the discovery that a mixture of trialkyl aluminum and dialkyl magnesium (or alkyl lithium) does not form an active polymerization catalyst with the supported titanium complex.

Furthermore, it has been found that other mixed metal alkyls, such as the mixture of dialkyl aluminum halide and alkyl zinc or the mixture of dialkyl aluminum halide and alkyl boron, also provide inactive polymerization catalysts.

DETAILED DESCRIPTION OF THE INVENTION

The catalyst system used in the process of the present invention contains a solid supported titanium complex component and a cocatalyst component which comprises a mixture of a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound

The titanium complex catalyst component may be any of the conventional solid titanium-containing complexes used in polymerizing alpha olefins, wherein the titanium is introduced into the complex without copulverization with the support. These titanium-containing catalyst components are well known in the art and are described, for example, in the aforementioned U.S. Pat. No. 4,143,223 and in Chemical Abstracts, 96:69614c (1982).

In general, the titanium complexes are obtained by contacting a titanium compound with a mechanically pulverized solid support, or carrier, in the absence of mechanical pulverization. Typically, the titanium compound will be a titanium tetrahalide, although other titanium compounds are suitable, such as alkoxytitanium halides. The preferred titanium compound is titanium tetrachloride.

The mechanically pulverized solid support will normally contain a magnesium compound, preferably a magnesium dihalide and more preferably, magnesium dichloride. Other magnesium compounds contemplated include alkoxy magnesium halides, aryloxy magnesium halides, and the like. Manganese dihalides may also be used in place of magnesium dihalides. The magnesium or manganese compounds should preferably be anhydrous.

Additionally, it is preferable to include a carboxylic acid ester in the final titanium complex. The carboxylic acid ester may be included as part of the pulverized solid support or it may be separately added to the titanium compound. Aromatic carboxylic acid esters are preferred, the most preferred being ethyl benzoate.

Other compounds have been variously described in the literature as useful in forming the titanium complexes. These compounds include alcohols such as ethanol; phenols such as cresol; and silicon tetrachloride. Often these compounds are introduced as part of the pulverized solid support.

The solid support may be mechanically pulverized in a ball mill, a vibratory mill, an impact mill, or the like, preferably under dry conditions in the absence of an inert diluent.

As used herein, the term "mechanically pulverized" or "mechanical pulverization" denotes pulverization which imparts a violent pulverizing effect to a material and excludes such means as mere mechanical stirring.

Suitable titanium complexes which are useful for forming the catalyst used in the present process include complexes comprising magnesium dichloride, ethyl benzoate, ethanol and titanium tetrachloride; complexes comprising magnesium dichloride, ethyl benzoate, cresol and titanium tetrachloride; and complexes comprising magnesium dichloride, ethyl benzoate, silicon tetrachloride and titanium tetrachloride.

The mixed metal alkyl component of the catalyst system of the present process comprises a mixture of a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound. The dialkyl aluminum halides which are suitable include dialkyl aluminum halides having the empirical formula: AlR.sub.2 X, where R is alkyl and X is halogen. Generally, the alkyl group will contain from 2 to 8 carbon atoms. Preferred dialkyl aluminum halides are the dialkyl aluminum chlorides. A preferred dialkyl aluminum chloride is diethyl aluminum chloride.

The dialkyl magnesium compounds suitable for use in the catalyst of the present process are those having alkyl groups of 2 to 8 carbon atoms. Representative examples include dioctyl magnesium, dipropyl magnesium, ethyl propyl magnesium, and the like. A preferred magnesium compound is dibutyl magnesium. Similarly, the alkyl lithium compounds suitable for use contain alkyl groups of 2 to 8 carbon atoms. Representative lithium compounds include ethyl lithium, propyl lithium, octyl lithium, and the like. A preferred lithium compound is butyl lithium.

The mixture of the dialkyl aluminum halide and the dialkyl magnesium or alkyl lithium compound has an aluminum to magnesium (or lithium) molar ratio of 1:5 to 5:1, preferably about 2:1. In a preferred embodiment, a small amount of a Lewis base is included in the aluminum-magnesium or aluminum-lithium mixture. Usually, from about 0.05 to 0.5 moles of Lewis base per mole of total aluminum plus magnesium, or total aluminum plus lithium, are sufficient. Preferred Lewis bases are the carboxylic acid esters, more preferably, the aromatic carboxylic acid esters. An especially preferred Lewis base is ethyl benzoate.

The alpha olefins are polymerized in contact with the present catalysts under conventional polymerization conditions. Polymerization is conducted at temperatures ranging from about 0.degree. C. to 100.degree. C., preferably from about 20.degree. C. to 70.degree. C. Polymerization pressure is generally about 3 to 16 atmospheres, preferably from about 5 to 10 atmospheres. The reaction is normally carried out over a period of about 1 to 24 hours.

The polymerization can be carried out either in the liquid or gaseous phase. When it is carried out in the liquid phase, an inert organic solvent can be used as a reaction medium or the olefin itself can be used as the reaction medium. Examples of inert organic solvents include aliphatic hydrocarbons of 4 to 8 carbon atoms such as hexane or heptane; cycloaliphatic hydrocarbons such as cyclohexane; and aromatics such as benzene, toluene or xylene.

In general, the alpha olefins suitable for use in polymerization include olefins having from about 2 to 8, preferably 2 to 5, carbon atoms. Typical olefins include ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene, and the like. The present catalyst system is particularly useful in the polymerization of propylene and 1-butene.

The regulation of the polymer molecular weight during the polymerization is effected according to known techniques by operating, for instance, in the presence of hydrogen. The presence of hydrogen as a molecular weight modifier, operating with the catalysts of the present invention, does not appreciably reduce the activity and/or stereospecificity of the catalysts.

The polymerization can be carried out by any of batchwise, semi-continuous or continuous methods. It is also possible to perform the polymerization in two or more stages under different reaction conditions.

The following examples are provided to illustrate the invention in accordance with the principles of the invention but are not to be construed as limiting the invention in any way except as indicated by the appended claims.

EXAMPLES

In the following examples, the amount of stereoregular polymer formed was determined by Soxhlet extraction of the total polymer product over a period of 6 hours. An n-heptane solvent was used for polypropylene and an ether solvent was used for poly-1-butene.

The specific viscosity was determined for poly-1-butene using a Decalin solvent at 115.degree. C. and a concentration of 0.1 g per 100 ml of solvent. The specific viscosity was determined for polypropylene using a Decalin solvent at 135.degree. C. and a concentration of 0.1 g per 100 ml of solvent.

Abbreviations used in the examples include "Et" for ethyl, "Bu" for butyl, and "i-Bu" for isobutyl.

EXAMPLE 1

Polymerizations were carried out in a 1-liter, stainless steel autoclave. Before each run, the autoclave was heated to 120.degree. C. for 2 hours and cooled to room temperature in dry, oxygen-free nitrogen. The propylene (99+%) used was dried over silica gel (Davison Grade 923) and the n-hexane solvent was dried over molsieve (Linde 1/16 inch pellets, 4A). All operations were performed under nitrogen.

The supported titanium complex used in this example was prepared according to the procedure described in Chemical Abstracts, 96:69614c (1982). Following this procedure, a mixture of 20 g MgCl.sub.2, 12 ml (12.62 g) ethyl benzoate and 3 ml (4.45 g) SiCl.sub.4 was ball milled for 46 hours to give a fine powder. An 8 g portion of the above powder was mixed with 400 ml 1,2-dichloroethane and 40 ml TiCl.sub.4 and heated at 80.degree. C. for 2 hours. The resulting complex was filtered, washed with n-hexane and dried in a nitrogen stream to give 5.78 g of catalyst containing 1.90 wt. % Ti.

For this example, the autoclave was charged with 163 g n-hexane, 1.4 mM AlEt.sub.2 Cl (25% solution in toluene), 0.7 mM MgBu.sub.2 (0.71 molar in heptane), 0.47 mM ethyl benzoate, and 0.031 g of an MgCl.sub.2 /ethyl benzoate/SiCl.sub.4 /TiCl.sub.4 (Ti=1.90%) catalyst (0.589 mg Ti; 0.0123 mM Ti), prepared as described above, and 125 g liquid propylene. The autoclave was heated to 50.degree. C. and was maintained at 50.degree. C. for 3 hours. When necessary, cooling was applied by an internal water coil. Following polymerization, the autoclave was vented and the product was washed with methanol and dried in vacuum at 70.degree.-80.degree. C. (Alternatively, the polymer could be isolated by evaporation of the solvent.) The polymer yield was 118 g, corresponding to 200,300 g polypropylene/g Ti. Propylene conversion was 94% and the yield of n-heptane insoluble polymer was 92%. The reduced specific viscosity was 4.4 dl/g.

EXAMPLES 2 to 16

Following the procedure of Example 1, 1-butene was polymerized with catalysts containing a titanium complex of magnesium dichloride, ethyl benzoate, ethanol and titanium tetrachloride, and a cocatalyst mixture of diethyl aluminum chloride and dibutyl magnesium. The results are shown in Table I. Various trialkyl aluminum cocatalysts are also shown for comparison.

The supported titanium complex designated "Catalyst A" in Table I was prepared according to the following procedure. Twenty grams of MgCl.sub.2, 6.3 g ethyl benzoate and 15.0 g ethanol was mixed in 100 ml dry n-pentane. The pentane was evaporated and the resulting solid was transferred into a centrifugal-type ball mill. The solid was ball milled for 1.5 hours, resulting in a fine powder. A 5 g portion of the above powder was mixed with 50 ml TiCl.sub.4 and was heated at 110.degree. C. for 2 hours. The mixture was filtered, an additional 50 ml TiCl.sub.4 was added and the mixture was reheated at 110.degree. C. for 2 hours. The resulting complex was filtered, washed with hexane and dried in a nitrogen stream to give a catalyst containing 4.12 wt. % Ti. The supported titanium complex designated "Catalyst B" in Table I was prepared in a similar manner.

TABLE I__________________________________________________________________________Polymerization of Pure 1-Butene With AlEt.sub.2 Cl + MgBu.sub.2.sup.a Reduced Ether Specific Yield Insoluble Viscosity,Example Catalyst.sup.c Cocatalyst.sup.b g g PB/g Ti % .eta..sub.sp /C__________________________________________________________________________2 A AlEt.sub.2 Cl + MgBu.sub.2 205.4 78,981 40.2 2.53 A AlEt.sub.2 Cl + MgBu.sub.2 + Et Benzoate 7.2 2,781 91.6 13.74 A AlEt.sub.2 Cl 0.8 312 -- 3.05 A MgBu.sub.2 Trace -- -- --6 A AlEt.sub.2 Cl + BEt.sub.3 Trace -- -- --7 A Al(i-Bu).sub.3 54.1 20,800 67.6 5.68 A Al(i-Bu).sub.3 + MgBu.sub.2 Trace -- -- --9 A Al(i-Bu).sub.3 + Et Benzoate 4.3 1,662 91.2 12.210 A AlEt.sub.3 Trace -- -- --11 A AlEt.sub.3 + MgBu.sub.2 Trace -- -- --12 B AlEt.sub.2 Cl + MgBu.sub. 2 237.0 91,269 61.4 1.813 B AlEt.sub.2 Cl + MgBu.sub.2 + Et Benzoate 229.0 88,150 76.0 2.514 B Al(i-Bu).sub.3 102.5 39,438 82.0 4.115 B Al(i-Bu).sub.3 + MgBu.sub.2 Trace -- -- --16 B Al(i-Bu).sub.3 + Et Benzoate 125.5 48,269 70.2 3.4__________________________________________________________________________.sup.a 100 ml n-hexane220 g 1-butene Room temperature, 1 hour2.6 mg Ti catalyst (0.054 mM.sup.b Al--alkyl = 5.60 mMMgBu.sub.2 = 2.80 mMEt Benzoate = 1.90 mM (Examples 3, 9)Et Benzoate = 0.32 mM (Examples 13, 16).sup.c A = MgCl.sub.2 --Et Benzoate-EtOH--TiCl.sub.4 ; Ti = 4.12%;Centrifugal-type ball mill ground supportB = MgCl.sub.2 --Et Benzoate-EtOH--TiCl.sub.4 ; Ti = 1.34%;Centrifugal-type ball mill ground support

EXAMPLES 17 to 25

Following the procedure of Example 1, a mixture of 50% 1-butene and 50% 2-butene was polymerized with catalysts containing a titanium complex of magnesium dichloride, ethyl benzoate, ethanol and titanium tetrachloride, and a cocatalyst mixture of diethyl aluminum chloride and dibutyl magnesium. The results are shown in Table II. Various trialkyl aluminum cocatalysts are also shown for comparison.

The supported titanium complexes designated "Catalyst B" and "Catalyst C" in Table II were prepared in a manner similar to that of "Catalyst A", described above.

TABLE II__________________________________________________________________________Polymerization of Mixed-Butene With AlEt.sub.2 Cl + MgBu.sub.2.sup.a Ether Yield InsolubleExample Catalyst.sup.c Cocatalyst.sup.b g g PB/g Ti %__________________________________________________________________________17 B AlEt.sub.2 Cl + MgBu.sub.2 97.6 37,538 40.018 B AlEt.sub.2 Cl + MgBu.sub.2 + Et Benzoate 13.4 5,154 84.419 B Al(i-Bu).sub.3 23.2 8,923 68.620 C AlEt.sub.2 Cl + MgBu.sub.2 92.0 35,392 28.421 C AlEt.sub.2 Cl + MgBu.sub.2 + Et Benzoate 7.6 2,931 82.422 C Al(i-Bu).sub.3 23.6 9,077 69.223 C Al(i-Bu).sub.3 + MgBu.sub.2 Trace -- --24 C AlEt.sub.3 10.5 4,027 5.0625 C AlEt.sub.3 + MgBu.sub.2 Trace -- --__________________________________________________________________________.sup.a 100 ml n-hexane220 g mixed-butene Room temperature, 1 hour2.6 mg Ti catalyst (0.054 mM Ti).sup.b Al--alkyl = 5.60 mMMgBu.sub.2 = 2.80 mMEt Benzoate = 0.63 mM.sup.c B = MgCl.sub.2 --Et Benzoate-EtOH--TiCl.sub.4 ; Ti = 1.34%;Centrifugal-type ball mill ground supportC = MgCl.sub.2 --Et Benzoate-EtOH--TiCl.sub.4 ; Ti = 3.93%;Ball mill ground support

Examples 26 to 36

Following the procedure of Example 1, propylene was polymerized with catalysts containing a titanium complex of magnesium dichloride, ethyl benzoate, ethanol and titanium tetrachloride, and a cocatalyst mixture of diethyl aluminum chloride and dibutyl magnesium. The results are shown in Table III. Trialkyl aluminum cocatalysts are also shown for comparison.

TABLE III__________________________________________________________________________Polymerization of Propylene With AlEt.sub.2 Cl + MgBu.sub.2.sup.a Reduced n-Heptane Specific Yield Insoluble Viscosity,Example Ti Catalyst.sup.c Cocatalyst.sup.b g g PP/g Ti % .eta..sub.sp /C__________________________________________________________________________26 A AlEt.sub.2 Cl + MgBu.sub.2 164.4 63,250 58.0 1.627 A AlEt.sub.2 Cl + MgBu.sub.2 + Et Benzoate 58.4 22,481 92.2 7.828 A AlEt.sub.2 Cl 15.9 6,131 49.0 2.329 A Al(i-Bu).sub.3 89.3 34,338 42.0 2.330 A Al(i-Bu).sub.3 + Et Benzoate 2.6 996 99.0 Insoluble31 C AlEt.sub.2 Cl + MgBu.sub.2 158.7 61,038 57.2 1.632 C AlEt.sub.2 Cl + MgBu.sub.2 + Et Benzoate 70.6 27,154 92.4 3.033 C AlEt.sub.2 Cl 18.7 7,192 44.0 --34 C Al(i-Bu).sub.3 144.0 55,385 45.0 1.435 C Al(i-Bu).sub.3 + MgBu.sub.2 7.0 2,692 64.6 --36 C Al(i-Bu).sub.3 + Et Benzoate 42.7 16,423 86.6 2.8__________________________________________________________________________ .sup. a 100 ml n-hexane 120 psi propylene,2.6 mg Ti catalyst (0.054 mM) 50.degree. C., 3 hours.sup.b Al--alkyl = 5.60 mMMgBu.sub.2 = 2.80 mMEt Benzoate = 1.90 mM.sup.c A = MgCl.sub.2 --Et Benzoate-EtOH--TiCl.sub.4 ; Ti = 4.12%;Centrifugal-type ball mill ground supportC = MgCl.sub.2 --Et Benzoate-EtOH--TiCl.sub.4 ; Ti = 3.93%;Ball mill ground support

EXAMPLES 37 to 56

Propylene, 1-butene, and a 50/50 mixture of 1-butene and 2-butene were polymerized following the procedure of Example 1. Various catalysts were employed containing a titanium complex and an alkyl aluminum cocatalyst. The results which are shown in Table IV demonstrate the effect of dibutyl magnesium on various alkyl aluminum cocatalysts. More specifically, Table IV shows that dibutyl magnesium activates alkyl aluminum halides for olefin polymerization while it completely deactivates aluminum trialkyls.

TABLE IV__________________________________________________________________________Effect of MgBu.sub.2 on Al--Alkyl Catalysts Reduced Yield Specific g Polymer/ Insoluble Viscosity,Example Monomer Catalyst* Cocatalyst g g Ti % .eta..sub.sp /C__________________________________________________________________________37 1-Butene A AlEt.sub.2 Cl 0.8 312 -- 3.038 1-Butene A AlEt.sub.2 Cl + MgBu.sub.2 205.4 78,981 40.2 2.539 1-Butene B AlEt.sub.2 Cl + MgBu.sub.2 237.0 91,269 61.4 1.840 1-Butene A AlEtCl.sub.2 None -- -- --41 1-Butene A AlEtCl.sub.2 + MgBu.sub.2 65.6 25,246 51.6 2.442 1-Butene A Al(i-Bu).sub.3 54.1 20,800 67.6 5.643 1-Butene A Al(i-Bu).sub.3 + MgBu.sub.2 Trace -- -- --44 1-Butene B Al(i-Bu).sub.3 102.5 39,438 82.0 4.145 1-Butene B Al(i-Bu).sub.3 + MgBu.sub.2 Trace -- -- --46 1-Butene A AlEt.sub.3 Trace -- -- --47 1-Butene A AlEt.sub.3 + MgBu.sub. 2 Trace -- -- --48 Mixed-Butene C AlEt.sub.2 Cl + MgBu.sub.2 92.0 35,392 28.449 Mixed-Butene C Al(i-Bu).sub.3 23.6 9,077 69.250 Mixed-Butene C Al(i-Bu).sub.3 + MgBu.sub.2 Trace -- -- --51 Mixed-Butene C AlEt.sub.3 10.6 4.027 50.652 Mixed-Butene C AlEt.sub.3 + MgBu.sub.2 Trace -- -- --53 Propylene C AlEt.sub.2 Cl 18.7 7,192 44.054 Propylene C AlEt.sub.2 Cl + MgBu.sub.2 158.7 61,038 57.255 Propylene C Al(i-Bu).sub.3 144.0 55,385 45.056 Propylene C Al(i-Bu).sub.3 + MgBu.sub.2 7.0 2,692 64.6__________________________________________________________________________ *A = MgCl.sub.2 --Et BenzoateEtOH--TiCl.sub.4 ; Ti = 4.12%; Centrifugaltype ball mill ground support B = MgCl.sub.2 --Et BenzoateEtOH--TiCl.sub.4 ; Ti = 1.34%; Centrifugaltyp ball mill ground support C = MgCl.sub.2 --Et BenzoateEtOH--TiCl.sub.4 ; Ti = 3.93%; Ball mill ground support

Examples 57 to 73

Following the procedure of Example 1, propylene was polymerized using various mixed metal alkyl cocatalysts. The results are summarized in Table V. Table V demonstrates that dialkyl magnesium and alkyl lithium provide active cocatalysts when combined with alkyl aluminum halides, whereas other metal alkyls, such as dialkyl zinc and trialkyl boron, give inactive cocatalysts when combined with alkyl aluminum halides. Table V further demonstrates that butyl lithium and dibutyl magnesium deactivate the otherwise active trialkyl aluminum cocatalysts.

The preparation of the supported titanium complex used in these examples (MgCl.sub.2 /Et Benzoate/SiCl.sub.4 /TiCl.sub.4 ; Ti=1.90%) is described in Example 1.

TABLE V__________________________________________________________________________Polymerization of Propylene.sup.a - Effect of Cocatalyst.sup.b Reduced n-Heptane Specific Yield Conv. Insoluble Viscosity,Example Cocatalyst (mM) g g PP/g Ti % % .eta..sub.sp /C__________________________________________________________________________57 AlEt.sub.2 Cl (1.4) 10.0 17,000 8.0 22.0 1.058 MgBu.sub.2 (0.7) 0.5 849 0.459 AlEt.sub.2 Cl/MgBu.sub.2 (1.4/0.7) 122.0 207,100 98.0 50.0 1.660 AlEt.sub.2 Cl/Mg(C.sub.6 H.sub.13).sub.2 (1.4/0.7) 28.0 47,500 22.0 55.0 2.461 AlEt.sub.2 Cl/LiBu (1.4/1.4) 86.0 146,000 69.0 52.0 1.562 AlEt.sub.2 Cl/ZnEt.sub.2 (1.4/0.7) 2.0 3,400 2.063 AlEt.sub.2 Cl/BEt.sub.3 (1.4/0.7) 7.0 11,900 6.0 2.364 AlEtCl.sub.2 (1.4) 0.0 0 0.0 0.065 AlEtCl.sub.2 /MgBu.sub.2 (1.4/0.7) 67.0 114,000 54.0 40.0 1.866 AlEtCl.sub.2 /MgBu.sub.2 (1.4/1.4) 23.0 39,000 18.0 59.0 2.267 Al(i-Bu).sub.3 (1.4) 119.0 202,000 95.0 40.0 1.668 Al(i-Bu).sub.3 /MgBu.sub.2 (1.4/0.7) 9.0 15,300 7.0 80.0 1.469 Al(i-Bu).sub.3 /Mg(C.sub.6 H.sub.13).sub.2 (1.4/0.7) 0.0 0 0.0 0.070 Al(i-Bu).sub.3 /LiBu (1.4/1.4) Trace Trace -- -- --71 AlEt.sub.3 (1.4) 78.0 132,400 62.0 48.0 2.472 AlEt.sub.3 /MgBu.sub.2 (1.4/0.7) 5.0 8,500 4.0 2.773 Al(i-Bu).sub.3 /MgBu.sub.2 /AlEt.sub.2 Cl (1.4/0.7/1.4) 99.0 168,100 79.0 40.0 2.1__________________________________________________________________________ .sup.a 163 g n-hexane 50.degree. C. 3 hoursg propylene.sup.b Catayst = 0.589 mg Ti (0.0123 mM);MgCl.sub.2 /Et Benzoate/SiCl.sub.4 /TiCl.sub.4 ;Ti = 1.90%

Examples 74 to 81

Following the procedure of Example 1, propylene was polymerized with catalysts containing various supported titanium tetrachloride complexes and mixed metal alkyl cocatalysts. The results are shown in Table VI. Table VI demonstrates the superior performance of the mixed metal alkyl cocatalysts, as compared to trialkyl aluminum cocatalysts, when combined with a broad range of supported titanium catalysts.

TABLE VI__________________________________________________________________________Polymerization of Propylene - Catalyst Comparison Ti in n-Heptane Propylene Catalyst Ti Time Temp. Yield InsolubleExample (99.9 + %) Catalyst % mg Cocatalyst (mM) hrs. .degree.C. g PP/g Ti %__________________________________________________________________________74 120 psi MgCl.sub.2 / 3.93 2.59 AlEt.sub.2 Cl 5.60 3 50 27,000 92 Et Benzoate/ MgBu.sub.2 2.80 EtOH/ Et Benzoate 1.90 TiCl.sub.475 120 psi MgCl.sub.2 / 3.93 2.59 Al(i-Bu).sub.3 5.60 3 50 16,000 87 Et Benzoate/ Et Benzoate 1.90 EtOH/ TiCl.sub.476 120 psi MgCl.sub.2 / 3.66 0.92 AlEt.sub.2 Cl 1.40 3 50 69,000 85 Et Benzoate/ MgBu.sub.2 0.70 o-Cresol/ Et Benzoate 0.47 TiCl.sub.477 120 psi MgCl.sub.2 / 3.66 0.92 Al(i-Bu).sub.3 1.40 3 50 32,000 86 Et Benzoate/ Et Benzoate 0.47 o-Cresol/ TiCl.sub.478 120 psi MgCl.sub.2 / 5.81 0.87 AlEt.sub.2 Cl 1.40 3 50 131,000 88 Et Benzoate/ MgBu.sub.2 0.70 SiCl.sub.4 / Et Benzoate 0.47 TiCl.sub.479 120 psi MgCl.sub.2 / 5.81 0.87 Al(i-Bu).sub.3 1.40 3 50 75,000 92 Et Benzoate/ Et Benzoate 0.47 SiCl.sub.4 / TiCl.sub.480 Liquid MgCl.sub.2 / 1.90 0.59 AlEt.sub.2 Cl 1.40 3 50 200,000 92 Et Benzoate/ MgBu.sub.2 0.70 SiCl.sub.4 / Et Benzoate 0.47 TiCl.sub.481 Liquid MgCl.sub.2 / 1.90 0.59 Al(i-Bu).sub.3 1.40 3 50 120,000 91 Et Benzoate/ Et Benzoate 0.47 SiCl.sub.4 / TiCl.sub.4__________________________________________________________________________

Examples 82 to 85

Following the procedure of Example 1, refinery propylene was polymerized using a cocatalyst mixture of diethyl aluminum chloride and dibutyl magnesium. The results are summarized in Table VII. A trialkyl aluminum cocatalyst is shown for comparison. Table VII demonstrates the superior performance of the mixed metal alkyl cocatalyst, as compared to trialkyl aluminum, in polymerizing propylene from a relatively impure refinery feed.

TABLE VII__________________________________________________________________________Polymerization of Refinery Propylene.sup.a__________________________________________________________________________ Reduced Cocatalyst Specific AlEt.sub.2 Cl/MgBu.sub.2 /Et n-Heptane SpecificTi.sup.b Benzoate Al(i-Bu).sub.3 /Et Benzoate Yield Conv. Insoluble Viscosity,Example mg mM mM g g PP/g Ti % % .eta..sub.sp /C__________________________________________________________________________82 0.589 1.4 0.7 0.47 57 97,000 46 89 2.883 1.178 2.8 1.4 0.94 106 90,000 85 92 4.084 1.178 2.8 1.4 1.29 75 63,700 60 9785 1.178 2.8 0.94 56 47,500 45 94__________________________________________________________________________Analysis ofRefinery PropyleneComponent %propylene 57.80propane 21.30isobutane 13.10n-butane 0.301-butene 1.70isobutylene 2.50trans-2-butene 0.45cis-2-butene 0.13__________________________________________________________________________ .sup.a 50.degree. C., 3 hours 51 g nhexane 216 g refinery propylene (125 g propylene) .sup.b Catalyst = MgCl.sub.2 /Et Benzoate/SiCl.sub.4 /TiCl.sub.4 ; Ti = 1.90%

Claims

1. A process for the stereoregular polymerization of alpha olefins which comprises polymerizing an alpha olefin having from 2 to 8 carbon atoms in the presence of a catalyst comprising:

(a) a solid supported titanium tetrahalide complex, wherein said complex is prepared by contacting a mechanically pulverized solid support with titanium tetrahalide in the absence of mechanical pulverization, and

(b) a cocatalyst comprising a mixture of a dialkyl aluminum halide and a dialkyl magnesium or alkyl lithium compound.

2. The process according to claim 1, wherein the polymerization is carried out at a temperature in the range of about 0.degree. C. to 100.degree. C. and a pressure in the range of about 3 to 16 atmospheres.

3. The process according to claim 2, wherein the polymerization is carried out at a temperature in the range of about 20.degree. C. to 70.degree. C. and a pressure in the range of about 5 to 10 atmospheres.

4. The process according to claim 1, wherein the alpha olefin is propylene.

5. The process according to claim 1, wherein the alpha olefin is 1-butene.

6. The process according to claim 1, wherein the dialkyl aluminum halide is a dialkyl aluminum chloride.

7. The process according to claim 6, wherein the dialkyl aluminum chloride is diethyl aluminum chloride.

8. The process according to claim 1, wherein the dialkyl magnesium compound is dibutyl magnesium.

9. The process according to claim 1, wherein the alkyl lithium compound is butyl lithium.

10. The process according to claim 1, wherein the molar ratio of aluminum to magnesium or aluminum to lithium is 1:5 to 5:1.

11. The process according to claim 1, wherein the cocatalyst further comprises a Lewis base.

12. The process according to claim 11, wherein the Lewis base is an aromatic carboxylic acid ester.

13. The process according to claim 12, wherein the Lewis base is ethyl benzoate.

14. The process according to claim 1, wherein the mechanically pulverized solid support comprises a magnesium dihalide, an aromatic carboxylic acid ester and an alcohol or phenol.

15. The process according to claim 1, wherein the the mechanically pulverized solid support comprises a magnesium dihalide, an aromatic carboxylic acid ester and silicon tetrachloride.

16. The process according to claim 14, wherein the titanium tetrahalide is titanium tetrachloride and the mechanically pulverized solid support comprises magnesium dichloride, ethyl benzoate and ethanol.

17. The process according to claim 14, wherein the titanium tetrahalide is titanium tetrachloride and the mechanically pulverized solid support comprises magnesium dichloride, ethyl benzoate and cresol.

18. The process according to claim 15, wherein the titanium tetrahalide is titanium tetrachloride and the mechanically pulverized solid support comprises magnesium dichloride, ethyl benzoate and silicon tetrachloride.