A process of preparing a solid catalyst component for the production of polypropylene includes a) dissolving a halide-containing magnesium compound in a mixture, the mixture including an epoxy compound, an organic phosphorus compound, and a hydrocarbon solvent to form a homogenous solution; b) treating the homogenous solution with an organosilicon compound during or after the dissolving step; c) treating the homogenous solution with a first titanium compound in the presence of a first non-phthalate electron donor, and an organosilicon compound, to form a solid precipitate; and d) treating the solid precipitate with a second titanium compound in the presence of a second non-phthalate electron donor to form the solid catalyst component, where the process is free of carboxylic acids and anhydrides.

The present disclosure is generally directed to polyolefin polymers, such as polypropylene homopolymers, and propylene-ethylene copolymers that have improved flow properties. In one embodiment, the polymers can be produced using a solid catalyst component that includes a) dissolving a halide-containing magnesium compound in a mixture, the mixture including an epoxy compound, an organic phosphorus compound, and a hydrocarbon solvent to form a homogenous solution; b) treating the homogenous solution with an organosilicon compound during or after the dissolving step; c) treating the homogenous solution with a first titanium compound in the presence of a first non-phthalate electron donor, and an organosilicon compound, to form a solid precipitate; and d) treating the solid precipitate with a second titanium compound in the presence of a second non-phthalate electron donor to form the solid catalyst component, where the process is free of carboxylic acids and anhydrides.

The present disclosure is generally directed to polyolefin polymers, such as polypropylene homopolymers, and propylene-ethylene copolymers that have improved flow properties. In one embodiment, the polymers can be produced using a solid catalyst component that includes a) dissolving a halide-containing magnesium compound in a mixture, the mixture including an epoxy compound, an organic phosphorus compound, and a hydrocarbon solvent to form a homogenous solution; b) treating the homogenous solution with an organosilicon compound during or after the dissolving step; c) treating the homogenous solution with a first titanium compound in the presence of a first non-phthalate electron donor, and an organosilicon compound, to form a solid precipitate; and d) treating the solid precipitate with a second titanium compound in the presence of a second non-phthalate electron donor to form the solid catalyst component, where the process is free of carboxylic acids and anhydrides.

The present invention discloses a Ziegler-Natta catalyst system for olefin polymerization, comprising at least one compound represented by formula (I) as (i) an internal electron donor, (ii) an external electron donor, or (iii) the both, wherein M.sub.1, M.sub.2, M.sub.3, M.sub.4, M.sub.5, M.sub.6, M.sub.1′, M.sub.2′, M.sub.3′, M.sub.4′, M.sub.5′ and M.sub.6′ are each independently selected from the group consisting of hydrogen, hydroxy, amino, aldehyde group, carboxy, acyl, halogen atoms, —R.sub.1 and —OR.sub.2, wherein R.sub.1 and R.sub.2 are each independently a C.sub.1-C.sub.10 hydrocarbyl, which is unsubstituted or substituted by a substituent selected from the group consisting of hydroxy, amino, aldehyde group, carboxy, acyl, halogen atoms, C.sub.1-C.sub.10 alkoxy and heteroatoms; and wherein, when among M.sub.1-M.sub.6 and M.sub.1′-M.sub.6′, any two adjacent groups on the same phenyl ring are each independently selected from the group consisting of R.sub.1 and —OR.sub.2, the two adjacent groups may optionally be linked to form a ring, with a proviso that M.sub.1, M.sub.2, M.sub.3, M.sub.4, M.sub.5, M.sub.6, M.sub.1′, M.sub.2′, M.sub.3′, M.sub.4′, M.sub.5′ and M.sub.6′ are not simultaneously hydrogen. ##STR00001##

The present invention discloses a Ziegler-Natta catalyst system for olefin polymerization, comprising at least one compound represented by formula (I) as (i) an internal electron donor, (ii) an external electron donor, or (iii) the both, wherein M.sub.1, M.sub.2, M.sub.3, M.sub.4, M.sub.5, M.sub.6, M.sub.1′, M.sub.2′, M.sub.3′, M.sub.4′, M.sub.5′ and M.sub.6′ are each independently selected from the group consisting of hydrogen, hydroxy, amino, aldehyde group, carboxy, acyl, halogen atoms, —R.sub.1 and —OR.sub.2, wherein R.sub.1 and R.sub.2 are each independently a C.sub.1-C.sub.10 hydrocarbyl, which is unsubstituted or substituted by a substituent selected from the group consisting of hydroxy, amino, aldehyde group, carboxy, acyl, halogen atoms, C.sub.1-C.sub.10 alkoxy and heteroatoms; and wherein, when among M.sub.1-M.sub.6 and M.sub.1′-M.sub.6′, any two adjacent groups on the same phenyl ring are each independently selected from the group consisting of R.sub.1 and —OR.sub.2, the two adjacent groups may optionally be linked to form a ring, with a proviso that M.sub.1, M.sub.2, M.sub.3, M.sub.4, M.sub.5, M.sub.6, M.sub.1′, M.sub.2′, M.sub.3′, M.sub.4′, M.sub.5′ and M.sub.6′ are not simultaneously hydrogen. ##STR00001##

Polymerization process control methods for making polyethylene are provided. The process control methods include performing a polymerization reaction in a polymerization reactor to produce the polyethylene, where ethylene, and optionally one or more comonomers, in the polymerization reaction is catalyzed by an electron donor-free Ziegler-Natta catalyst and an alkyl aluminum co-catalyst. A melt flow ratio (I.sub.21/I.sub.2) of the polyethylene removed from the polymerization reactor is measured and an amount of long chain branching (LCB) of the polyethylene from the polymerization reactor is controlled by adjusting a weight concentration of the alkyl aluminum co-catalyst present in the polymerization reactor. In addition, an electron donor-free Ziegler-Natta catalyst productivity of the polyethylene being produced in the polymerization reactor is measured from which the amount of LCB of the polyethylene from the polymerization reactor is determined using the measured electron donor-free Ziegler-Natta catalyst productivity and a predetermined relationship between the electron donor-free Ziegler-Natta catalyst productivity and the LCB.

Polymerization process control methods for making polyethylene are provided. The process control methods include performing a polymerization reaction in a polymerization reactor to produce the polyethylene, where ethylene, and optionally one or more comonomers, in the polymerization reaction is catalyzed by an electron donor-free Ziegler-Natta catalyst and an alkyl aluminum co-catalyst. A melt flow ratio (I.sub.21/I.sub.2) of the polyethylene removed from the polymerization reactor is measured and an amount of long chain branching (LCB) of the polyethylene from the polymerization reactor is controlled by adjusting a weight concentration of the alkyl aluminum co-catalyst present in the polymerization reactor. In addition, an electron donor-free Ziegler-Natta catalyst productivity of the polyethylene being produced in the polymerization reactor is measured from which the amount of LCB of the polyethylene from the polymerization reactor is determined using the measured electron donor-free Ziegler-Natta catalyst productivity and a predetermined relationship between the electron donor-free Ziegler-Natta catalyst productivity and the LCB.

To produce an olefin-based polymer having a minor amount of decrease in bulk density due to heat.

A solid catalyst component for olefin polymerization containing a titanium atom, a magnesium atom, a halogen atom, and as internal electron donor, and having an envelope E1 calculated by the following Formula (1) in a range of 0.810 to 0.920.

E1=LE1/LS1   (1)

(In Formula, LE1 is a convex hull perimeter of the solid catalyst component for olefin polymerization obtained from an image of the solid catalyst component for olefin polymerization captured with a scanning electron microscope, and LS1 is an actual perimeter of the solid catalyst component for olefin. polymerization obtained from the image of the solid catalyst component for olefin polymerization captured with the scanning electron microscope.)

To produce an olefin-based polymer having a minor amount of decrease in bulk density due to heat.

A solid catalyst component for olefin polymerization containing a titanium atom, a magnesium atom, a halogen atom, and as internal electron donor, and having an envelope E1 calculated by the following Formula (1) in a range of 0.810 to 0.920.

E1=LE1/LS1   (1)

(In Formula, LE1 is a convex hull perimeter of the solid catalyst component for olefin polymerization obtained from an image of the solid catalyst component for olefin polymerization captured with a scanning electron microscope, and LS1 is an actual perimeter of the solid catalyst component for olefin. polymerization obtained from the image of the solid catalyst component for olefin polymerization captured with the scanning electron microscope.)

Polymerization process control methods for making polyethylene are provided. The process control methods include performing a polymerization reaction in a polymerization reactor to produce the polyethylene, where ethylene, and optionally one or more comonomers, in the polymerization reaction is catalyzed by an electron donor-free Ziegler-Natta catalyst and an alkyl aluminum co-catalyst. A melt flow ratio (I.sub.21/I.sub.2) of the polyethylene removed from the polymerization reactor is measured and an amount of long chain branching (LCB) of the polyethylene from the polymerization reactor is controlled by adjusting a weight concentration of the alkyl aluminum co-catalyst present in the polymerization reactor. In addition, an electron donor-free Ziegler-Natta catalyst productivity of the polyethylene being produced in the polymerization reactor is measured from which the amount of LCB of the polyethylene from the polymerization reactor is determined using the measured electron donor-free Ziegler-Natta catalyst productivity and a predetermined relationship between the electron donor-free Ziegler-Natta catalyst productivity and the LCB.