Catalyst support and related processes

Abstract

The present invention describes a catalyst support, which is used as an inorganic carrier for a Ziegler-Nata catalyst (ZN), using a modified spray cooling method. Such a catalyst support is prepared from alcoholic solutions of (a) an inorganic compound, in which the inorganic compound is a magnesium compound and (b) an inorganic compound and one or more additives. The solutions are prepared at a temperature below 100 C., carried through a nozzle placed inside a reactor, and sprayed into droplets forming a solid precipitate, which is generally spherical, when in contact with an inert hydrocarbon solvent at low temperature. The obtained catalyst support is reacted with a titanium compound, preferably titanium tetrachloride, in order to produce an active catalyst for olefin polymerization.

Claims

1. A catalyst support component comprising an inorganic compound, an alcohol ROH, and an additive, wherein the catalyst support component has a first thermal transition peak between 112 C. and 150 C. as shown by DSC, and at least one peak as shown by X-Ray diffraction, wherein only one peak is in the range from 0 to 10.

2. The catalyst support component of claim 1, wherein the alcohol ROH consists of a R chosen from a C1-C18 hydrocarbon group.

3. The catalyst support component of claim 1, wherein the additive is a non-polymeric additive.

4. The catalyst support component of claim 3, wherein the non-polymeric additive is a fluorine-based additive.

5. The catalyst support component of claim 1, wherein the additive is selected from one or more of hydrofluoroalkenes (HFAs), polyaryletherketone (PAEK) derivatives, poly(oxy-1,2-ethanediyl) derivatives, aliphatic polyethers, polylactic acid, or polysorbates.

6. The catalyst support component of claim 4, wherein the additive is fluorine-based and selected from the group consisting of perfluoropentane; 1,1,1,2-tetrafluorethane; 1,1,1,2,3,3,3-heptafluoropentane; 1,1,1,2,2,3,4-heptafluoropentane; 1,1,1,2,2,3,4-heptafluorobutane; 1,1,3,3,4,4-hexafluorobutane; 1,1,1,2,3,4-hexafluorobutane; 1,1,1,2,2,3,3,4,4-nonafluorohexane; 1,1,1,2,2,3,3,4,5-nonafluorohexane; 1,1,1,2,2,3,3,4-octafluoropentane; 1,1,1,2,2,3,5-heptafluoropentane; 1,1,1,2,2,3,4,5-octafluoropentane; 1,1,1,2,2,4,4,5,5-nonafluoropentane, and 1,1,1,2,3,4,4,5,5,5-decafluoropentane.

7. A process for the polymerization of olefins comprising contacting a monomer with an activated catalyst produced with the catalyst support component of claim 4.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will be described by way of example with reference to the accompanying drawings.

(2) FIG. 1 is an illustration of the apparatus used to prepare catalytic support.

(3) FIG. 2 is a DSC thermogram of the supports SSB01 to SSB08.

(4) FIG. 3 displays powder X-ray diffraction patterns of MgCl.sub.2 and support samples SSB01 to SSB08.

(5) FIG. 4 displays thermogravimetric analysis (TGA) of support samples SSB01 to SSB08.

(6) FIG. 5 are images obtained by Scanning Electron Microscope (SEM).

DETAILED DESCRIPTION OF THE INVENTION

(7) For purposes of the description hereinafter, it is to be understood that the embodiments described below may assume alternative variations and embodiments. It is also to be understood that the specific articles, compositions, and/or processes described herein are exemplary and should not be considered as limiting.

(8) The present invention describes a catalytic support prepared using a modified Spray Cooling method. The production system is exemplified in FIG. 1, which illustrates the process steps to transfer, spray, and precipitate to obtain spherical inorganic particles used to support a ZN catalyst. The solution is first prepared in the reactor A (1). The solution is transferred through inch tubing (2) containing a jacket to control temperature during the transfer of the solution (3). The size and shape of the droplets produced by the atomizer are controlled by the liquid pressure (4) and gas pressureoptional (5). The type of atomizer (6) is not limited and different types can be explored according to the scale and conditions of the experiment. The crystallization of the particle occurs through the contact of the droplets of alcoholic solution with the inert hydrocarbon liquid at low temperature in the reactor B (7). All steps were conducted under nitrogen or argon atmosphere. In the examples described in this invention the catalyst supports are produced using two nozzle systems: gas atomizing and hydraulic spray nozzle. In the case of using gas atomizing the atomization is produced by combination of inert gas and liquid pressures. In the case of using hydraulic spray nozzle the atomization is produced by liquid pressure.

(9) The catalyst support produced by the modified Spray Cooling method is prepared from an alcoholic solution comprising an inorganic compound, an alcohol ROH, and an additive to increase the solubility of the inorganic compound in the alcohol ROH:

(10) In some embodiments, the inorganic compound can be a magnesium compound (such as a magnesium halide or/and magnesium alkoxide) which can be mixed with alcohol to form a solution. The alcohol has the formula ROH, wherein R is a C1-C18 hydrocarbon group, which enables the use of a different alcohol and therefore different molar ratios. For example, the alcohol can be methanol, ethanol, propanol, iso-propanol, butanol, isobutanol, 2-ethylhexanol, chloroethanol, 2,2,2-trichloroethanol. The resulting mixture can be stirred at a temperature from 30 C. to 100 C., more specifically from 50 C. to 70 C. to form the alcoholic solution.

(11) The inorganic compound (e.g., magnesium compounds, such as magnesium halide or/and magnesium alkoxide) is mixed with alcohol and one or more additives, in which the additives can be fluorine based compounds such as hydrofluoroalkenes (HFAs) or other compounds such as polyaryletherketone (PAEK) derivatives, poly(oxy-1,2-ethanediyl) derivatives, aliphatic polyether, polylactic acid, and polysorbates. Examples of fluorine based compounds include: 2H, 3H perfluoropentane; 1,1,1,2-tetrafluorethane; 1,1,1,2,3,3,3-heptafluoropentane; 1,1,1,2,2,3,4-heptafluoropentane; 1,1,1,2,2,3,4-heptafluorobutane; 1,1,3,3,4,4-hexafluorobutane; 1,1,1,2,3,4-hexafluorobutane; 1,1,1,2,2,3,3,4,4-nonafluorohexane; 1,1,1,2,2,3,3,4,5-nonafluorohexane; 1,1,1,2,2,3,3,4-octafluoropentane; 1,1,1,2,2,3,5-heptafluoropentane; 1,1,1,2,2,3,4,5-octafluoropentane; and 1,1,1,2,2,4,4,5,5-nonafluoropentane, 1,1,1,2,3,4,4,5,5,5-decafluoropentane. Other examples of additives include: sorbitan trifoliate, sorbitan monooleate, sorbitan monolaurate, polyoxyethylene sorbitan monolaurate, polyethylene sorbitan monooleate, natural lecithin, oleyl polyoxyethylene ether, stearyl polyoxyethylene ether, lauryl polyoxyethylene ether, block copolymers of oxyethylene and oxypropylene, oleic acid, synthetic lecithin, diethylene glycol dioleate, tetrahydrofurfuryl, oleate, ethyloleate, isopropyl myristate, glyceryl monooleate, glyceryl monostearate, glyceryl monoricinoleate, cetyl alcohol, polyethylene glycol, polyoxypropylene glycol, cetyl pyridinium chloride, olive oil, glyceryl monolaurate, polyoxyethylene nonyl phenolether, polyoxyetheylene monolaurate, polyoxyethylene dilaurate, polyoxyethylene stearyl ether, polyethylene glycol-b-polypropylene, oleic acid, polyetheretherketone, polyetherketone, polyetherketoneketone, polyetherketoneetherketoneketone, polyetheretherketoneketone. The amount of additive in the catalyst support can be between 0.01 to 20 wt %. The alcohol ROH, wherein R is a C1-C18 hydrocarbon group.

(12) The resulting alcoholic solutions described above can be aerosolized by spraying them through a nozzle, which is placed inside the reactor, as represented in FIG. 1. The aerosolized solutions can form a precipitate when contacted with an inert liquid at low temperature, between 30 C. to 0 C. As a result, generally spherical particles are obtained, as shown in FIG. 5.

(13) The non-solvent or inert liquid can be a aliphatic and aromatic hydrocarbon. The aliphatic hydrocarbon is selected from the group consisting of isoparaffin, hexane, heptane, octane, nonane, decane, cyclohexane or mixture of two or more hydrocarbon. The aromatic hydrocarbon is selected from benzene, toluene, xylene or the mixture of two or more hydrocarbon.

(14) The resulting catalytic support can be subjected to a heat treatment in order to remove the excess of alcohol or additive compound or compounds. The amount of alcohol removed should correspond to a composition, in which the inorganic support obtained shows a molar ratio of at least 0.5 mol of alcohol per mol of MgCl.sub.2.

(15) The catalyst for olefin polymerization is prepared by the reaction between the catalyst support as described above with one or more titanium halides. Examples of the titanium halide include, but are not limited to, titanium tetrachloride, titanium tetrabromide, tetrabutoxy titanium, tetraethoxy titanium, tributoxy titanium chloride, dibutoxy titanium dichloride, and triethoxy titanium. Titanium halide compounds include those having chlorine (as titanium tetrachloride). The titanium halide can be used alone or in the presence of inert solvent. In some embodiments, the titanium halide component is added with an internal donor compound such as a phthalate, succinate, diether, benzoate or chemically similar compound.

(16) Embodiments of catalyst supports described in the present application were obtained from alcoholic solutions of, comprising: (a) an inorganic compound, being a magnesium compound and (b) an inorganic compound and one or more additives through a modified spray cooling technique to form generally spherical particles having differentiated physical properties compared known catalyst supports.

(17) Some physical properties are exemplified in FIG. 2. DSC thermograms of inventive supports SSB01 to SSB08 have endothermic peaks at three different transition temperatures. The thermal transition A occurs between 112 C. and 154 C.; thermal transition B occurs between 181 C. and 215 C.; and thermal transition C occurs between 235 C. and 248 C.

(18) In order to evaluate the effect of the aerosolization method, different types of nozzles were used resulting in two different catalyst support SSB04 (example 4) and SSB05 (example 5). The sample SSB04 was obtained by the passage of the resulting alcoholic solution through a gas atomizing nozzle. The catalyst support SSB05 was produced by the hydraulic spray nozzle. The DSC thermograms show distinguishable thermal events between SSB04 and SSB05, however in both cases, the main endothermic peaks occurred at temperatures above 112 C.

(19) In another embodiment, magnesium halide was mixed with an additive mono-(9Z)-9-octadecenoate, poly(oxy-1,2-ethanediyl) derivative (MOP) in the presence of an alcohol to obtain sample SSB06 (having 1.4 wt % of MOP Example 06), and sample SSB07 having 4.8 wt % of MOP (Example 07). As shown in FIG. 2, the addition of MOP in the initial alcoholic solution alters the endothermic peaks of the final particles.

(20) In yet another embodiment, an alcoholic solution was prepared with MgCl.sub.2, 1.3 wt % of MOP, and 28.4 wt % of fluorine based compound 1,1,1,2,3,4,4,5,5,5-decafluoropentane to produce sample SSB08 (Example 8). As shown in FIG. 2, the addition of 1,1,1,2,3,4,4,5,5,5-decafluoropentane further altered the endothermic peaks of the final particles in a solution having MOP.

(21) The inventive examples described herein were also analyzed by X-ray diffraction analysis. As shown in FIG. 3, the diffraction patterns of the catalyst supports (SSB01-SSB08) are different for different experiment conditions and also when compared to anhydrous MgCl.sub.2, which exhibits a cubic close packing structure that gives strong 20 peaks at 15, 35, and 50.4.

(22) Examples 01 to 03 describe catalyst supports SSB01 to SSB03, respectively, and show broad diffraction features observed at around 5.6-6.1. These results suggest the presence of an amorphous region in the obtained inorganic particle. Furthermore, comparing the results mentioned in the cited patents, the obtained inorganic particles showed additional XRD peaks with high intensity 20 at 8.8 and 9.4 for SSB01 and 8.3 for SSB02. The support SSB03, as described in example 3, was subjected to a thermal treatment for partial elimination of alcohol and showed a different diffraction pattern without a high intensity peak below 10. High intensity reflection below 10 characterizes alcohol interaction along the z-axis of layered structure of rhombohedral MgCl.sub.2.

(23) In order to evaluate the effect of the produced inorganic particle by different types of nozzles, samples SSB04 and SSB05 were prepared as described in the examples 4 and 5, respectively. The diffraction spectrum of these supports did not show high intensity diffraction peaks at 20 above 10, more specifically in between 10 and 50. In particular, the sample SSB04 showed a single peak of greater intensity at 2=8.9 and a discrete peak at 2=9.4. In contrast, sample SSB05 showed a single low angle peak (<10), which was 2=8.3. In the final three samples, it is important to mention that the introduction of additives aiming to improve the incorporation of MgCl.sub.2 using alcohol as a solvating agent, systematically showed at least one low angle high intensity peak)(<10. Sample SSB06, using 1.4 wt % of MOP, showed 2 diffraction peaks at 8.9 and 9.3. Otherwise, samples SSB07 and SSB08 showed a single crystalline 2 peak at 8.9 and 8.4, respectively. Therefore, samples prepared as described in example 6 to 8 showed very unique diffraction patterns. Although the additives improve the incorporation of MgCl.sub.2 in alcohol, which act mainly as a solvation agent, they did not disturb crystalline adduct formation at low angle diffraction peaks. Furthermore, the results obtained in samples SSB05, SSB07, and SSB08 showed a single crystalline peak at 2 below 10.

(24) Support Preparation

(25) In some embodiments of the process to prepare a catalyst support, the catalyst support can be prepared according to steps, comprising:

(26) Step 1: Preparation of Alcoholic Solution

(27) To prepare a solution of inorganic compound (e.g., magnesium compound) (4 wt % to 50 wt %) by dissolving in alcohol ROH with one or more additives (5 wt % to 50 wt %), which acts as solvation agent, all the components are added to a glass reactor (FIG. 1) and the solution is prepared at temperatures below 100 C. (e.g., between 30 C. to 80 C.) under inert atmosphere (nitrogen or argon) in a stirring system using mechanical or magnetic stirrer (e.g., between 100 RPM and 600 RPM).

(28) Step 2: Preparation of the Support

(29) The solution is stirred under a nitrogen atmosphere, slightly pressurized (1-5 bar) at a temperature below 100 C. (e.g., between 30 C. to 80 C.). The glass reactor is then connected to a transfer line or jacketed tubing, where the temperature is equal to or slightly higher than the temperature of the alcoholic solution. The transfer line is then connected to a nozzle (e.g., an atomizer) kept inside a second reactor (e.g., reactor B of FIG. 1), which contains a non-solvent liquid at low temperature (30 C. to 10 C.) under inert atmosphere (nitrogen or argon) slightly pressurized, which pressure is lower than a first reactor (e.g., reactor A of FIG. 1), and stirred using a mechanical stirrer (e.g., 100 RPM to 600 RPM). The alcoholic solution is transferred to the atomizer due to the higher pressure in first reactor (e.g., reactor A of FIG. 1)) and sprayed in a downward vertical direction into small droplets (See, e.g., the atomizer/nozzle in reactor B of FIG. 1), which precipitate as generally spherical particles when in contact with the non-solvent liquid at low temperature (e.g., 30 C. to 10 C.).

(30) The resulting suspension of generally spherical particles and the non-solvent liquid is stirred (e.g., 100 RPM to 600 RPM) at low temperature (e.g., 30 C. to 10 C.) for several hours (e.g., 0.1 h to 6 h) before slowly warming the suspension to room temperature. The rate of crystallization of catalyst support depends upon residence time in the liquid medium (e.g., in Reactor B of FIG. 1) the stirring conditions (e.g., rate of rotation), and temperature, which affects the morphology and mechanical strength of the final solid particle. As a result, these conditions can produce catalyst supports with different crystalline structures.

(31) The agitation/stirring is stopped to allow the spherical particles to settle to the bottom of the reactor. The excess non-solvent liquid is separated via cannula under inert atmosphere (e.g., nitrogen or argon) followed by the addition of excess hexane or heptane to transfer the resulting suspension to a Schlenk filter flask. Then, the non-solvents are flushed through the bottom of the flask under inert atmosphere (e.g., nitrogen or argon) retaining the generally spherical particles on the filter.

(32) The procedure is followed by an addition of hexane or heptane, which is stirred for 30 minutes under inert atmosphere and the liquids are flushed through the bottom of the Schlenk flask. This process is repeated several times (e.g., 1 to 10 times) until the residual non-solvent is removed. The resulting spherical particles are then dried under nitrogen or argon flow for several hours (e.g., 1 h to 12 hs) to obtain the catalyst support.

(33) Step 3: Thermal Treatment (Optional)

(34) The spherical particles are added to or kept in a Schlenk filter flask under inert atmosphere (nitrogen or argon). The flask is placed inside an oven at initial temperature below 80 C. and under nitrogen or argon flow fluidizing the spherical support on the filter of the Schlenk flask. The thermal treatment can be carried out under isothermal conditions for several hours (e.g., 0.1 h to 12 hs) or temperature ramps can be performed up to 250 C. with ramp rates from 0.1 C./min to 100 C./min. Then, the spherical particles are cooled down to room temperature at cooling rates from 0.1 C./min to 100 C./min to obtain the catalyst support.

EXAMPLES

Example 1

(35) A solution of MgCl.sub.2 anhydride in ethanol at 4.0 wt % was prepared at room temperature. This solution was transferred through OD jacketed tubing with controlled temperature connected to an atomizer (gas atomizer nozzle) placed inside a 5 L rounded-bottom flask to spray droplets of the alcoholic solution to dried isoparaffin at low temperature, approximately 20 C. The pressure applied in reactor A (1) and system (4) to transfer initial alcoholic solution to the atomizer was 0.7 bar, while the N.sub.2 pressure (5) was 1.0 bar. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 RPM. After stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. The resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB01.

Example 2

(36) A solution of MgCl.sub.2 anhydride in ethanol at 12.2 wt % was prepared at 60 C. This solution was transferred through OD jacketed tubing with controlled temperature directly to a 5 L rounded-bottom flask without the use of the atomizer. The alcoholic solution was transferred to dried isoparaffin at low temperature, at approximately 20 C. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 RPM. After stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. The resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB02.

Example 3

(37) The support catalyst was prepared as described in Example 2, followed by an additional step to remove the excess of ethanol from the obtained particles through a thermal treatment, as follows: the support was transferred to a Schlenk filter and kept under countercurrent nitrogen flow inside an oven for 1 hour at each temperature 40 C., 50 C. and, 60 C. to obtain support SSB03.

Example 4

(38) A solution of MgCl.sub.2 anhydride in ethanol at 12.2 wt % was prepared at 60 C. This solution was transferred through OD jacketed tubing with controlled temperature connected to an atomizer (gas atomizer nozzle) placed inside a 5 L rounded-bottom flask to spray droplets of the alcoholic solution to dried isoparaffin at low temperature, approximately 20 C. The pressure applied in reactor A (1) and system (4) to transfer initial alcoholic solution to the atomizer was 0.7 bar, while the N.sub.2 pressure (5) was 1.0 bar. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 RPM. After stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. Then, the resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB04.

Example 5

(39) A solution of MgCl.sub.2 anhydride in ethanol at 12.5 wt % was prepared at 60 C. This solution was transferred through OD jacketed tubing with controlled temperature connected to an atomizer (hydraulic spray nozzle) and placed inside a 5 L rounded-bottom flask to spray droplets of the alcoholic solution to dried isoparaffin at low temperature, approximately 20 C. The pressured applied in reactor A (1) and system (4) to transfer initial alcoholic solution to the atomizer was 1.0 bar. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 RPM. After stopping the stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. Then, the resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB05.

Example 6

(40) A solution of MgCl.sub.2 anhydride in ethanol at 15.6 wt % was prepared at 60 C. In this solution was added 1.4 wt % of MOP and then transferred through OD jacketed tubing with controlled temperature connected to an atomizer (hydraulic spray nozzle) placed inside a 5 L rounded-bottom flask to spray droplets of the alcoholic solution to dried isoparaffin at low temperature, approximately 20 C. The pressure applied in reactor A (1) and system (4) to transfer initial alcoholic solution to the atomizer was 1.0 bar. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 RPM. After stopping the stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. Then, the resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB06.

Example 7

(41) A solution of MgCl.sub.2 anhydride in ethanol at 18.0 wt % was prepared at 60 C. In this solution was added 4.8 wt % of MOP and then transferred through OD jacketed tubing with controlled temperature connected to an atomizer (hydraulic spray nozzle) placed inside a 5 L rounded-bottom flask to spray droplets of the alcoholic solution to dried isoparaffin at low temperature, approximately 20 C. The pressured applied in reactor A (1) and system (4) to transfer initial alcoholic solution to the atomizer was 1.0 bar. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 rpm. After stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. The resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB07.

Example 8

(42) A solution of MgCl.sub.2 anhydride in ethanol at 15.6 wt % was prepared at 70 C. In this solution was added 1.3 wt % of MOP and 28.4 wt % of 1,1,1,2,3,4,4,5,5,5-decafluoropentane. The resulting solution was transferred through OD jacketed tubing with controlled temperature connected to an atomizer (hydraulic spray nozzle) placed inside a 5 L rounded-bottom flask to spray droplets of the alcoholic solution to dried isoparaffin at low temperature, approximately 20 C. The pressure applied in reactor A (1) and system (4) to transfer initial alcoholic solution to the atomizer was 1.0 bar. The resulting suspension of the particles precipitated in isoparaffin was stirred overnight at 350 RPM. After stirring, the mixture was left for 3 hours and then the supernatant was removed and 1 L of dried hexane was added to form a suspension with the resulting particles. The resulting mixture was transferred through cannula to a Schlenk flask followed by the filtration and recovering of the particles, which was washed several times with anhydride hexane and dried under nitrogen flow. All steps of this experiment were carried out under N.sub.2 atmosphere to obtain support sample SSB08.

(43) Catalyst Synthesis

Example 9

(44) To a 300 mL Schlenk flask equipped with a sealed mechanical stirrer under N.sub.2 atmosphere, 100 ml of TiCl.sub.4 was added and the temperature was cooled down to 0 C. Then, 5.7 g of support (obtained from example 1 to 8) was added and the mixture was stirred at 350 RPM followed by the dropwise addition of 22 ml of diisobutyl phthalate in hexane 10 wt %. The temperature of the reactive mixture was increased to 100 C. and stirred for 1 hour. The unreacted TiCl.sub.4 and its residues were removed by filtration followed by an additional 100 ml of TiCl.sub.4 to remove undesired remain residues. Thus, the resulting suspension was stirred for 1 hour at 120 C. and filtered again. The solid catalyst was washed several times with anhydride hexane at 60 C. and dried under N.sub.2 to obtain catalysts SCB01 to SCB08, except for SCB05, which support sample SSB05 was contaminated during the experiment. All residual TiCl.sub.4 was quenched with ethanol/hexane mixture.

(45) Polymerization of Propylene

Example 10

(46) Propylene polymerizations were performance in bulk using a 3.8 L stainless-steel reactor equipped with a mechanical stirrer, a manometer, a temperature indicator, a system for feeding the catalyst, monomer supply line, and a jacket for thermostatic temperature control. First, in a flask under N.sub.2 atmosphere, 10 mg of catalyst was dispersed in 70 ml of hexane and then hexane solutions of triethyl aluminium 10 wt % and cyclohexylmethyl-dimethoxysilane 5 wt % were added. The pre-contact was left under stirring for 10 minutes. For propylene polymerization, the reactor was purged with nitrogen flow at 70 C. for 1 hour; then the catalyst dispersion was introduced into the reactor under N.sub.2 flow at 30 C. Hereafter, H.sub.2 (1 bar) and 2.3 kg of liquid propylene were fed under stirring. The temperature was raised to 70 C. and the polymerization was carried under this condition for 2 hours. The unreacted propylene was flashed off and the resulting polymers SCB01-PP to SCB08-PP were recovered and dried at 70 C. under vacuum.

(47) The application of the catalyst system of the present study is not limited by propylene polymerization. It can be applied in polymerization of other olefins.

(48) Characterization

(49) The obtained supports were characterized by atomic absorption spectrometry analysis (AA) by Spectra A 50B Varian, potentiometric titration was carried out in a 808 Titrando Metrohm and Ultraviolet-visible spectrophotometry (UV-vis) in a Cary 100 Conc.

(50) Varian to quantify Mg (%), Cl (%); For thermal properties an evaluation sample was prepared in aluminum pans under nitrogen atmosphere to avoid exposure to moisture and analyzed by a differential scanning calorimeter (DSC) TA instrument, at a scanning rate of 10 C./min in the range 25 C. to 300 C. The samples were characterized by a Rigaku D/Max 2100 Powder X-ray Diffractometer Cu K radiation (=1.5405 ) with a diffracted beam graphite monochromator. Scanning electron microscope (SEM) images were performed using TM1000Hitach (Low Vacuum). Support and catalyst average particle size and particle size distribution were carried out by a laser light diffraction method using Apparatus Master Sizer Hydro 2000S from Malvern.

(51) The resulting polypropylene xylenes solubles (XS) were measured according to standard ASTM D 5492-06. Pentad analyses were carried out by .sup.13C NMR spectrum in an Agilent 500 MHz at 120 C. in TCE-d/ODCB-d (1:1 v/v) equipped with a 5 mm probe. Gel permeation chromatography (GPC) was carried out on Alliance GPC 2000 from Waters using TCB as a solvent at 140 C. after calibration with standard polystyrene samples. Polymer powder measurements were carried out according to ASTM D 1921-06.

(52) TABLE-US-00001 TABLE 1 Elementary analysis of catalyst support (Mg) Cl Support (%) (%) SSB01 7.4 28.7 SSB02 8.6 35.7 SSB03 10.3 41.8 SSB04 8.0 29.7 SSB05 11.7 37.1 SSB06 8.8 56.0 SSB07 7.8 46.7 SSB08 7.3 22.1

(53) TABLE-US-00002 TABLE 2 Elementary analysis of catalyst (Mg) Cl Ti Catalyst.sup.a (%) (%) (%) SCB01 16.2 58.6 5.8 SCB02 13.8 58.9 6.4 SCB03 14.6 58.4 5.3 SCB04 13.3 55.1 5.6 SCB05.sup.b NA NA NA SCB06 13.3 56.0 6.9 SCB07 6.3 45.7 11.4 SCB08 7.6 42.4 10.4 .sup.aCatalysts SCB01 to SCB08 were prepared from their correspondent supports number SSB01 to SSB08. .sup.bThe support SSB05 was not used to prepare catalyst.

(54) TABLE-US-00003 TABLE 3 Average particle diameter and Span D50 Catalyst.sup.a (m) Span SCB01 24 2.8 SCB02 90 2.0 SCB03 122 1.9 SCB04 45 2.8 SCB05 NA NA SCB06 72 1.8 SCB07 50 2.4 SCB08 54 2.3 .sup.aCatalysts SCB01 to SCB08 were prepared from their correspondent supports number SSB01 to SSB08, except from support SSB05 which was not used to prepare catalyst.

(55) TABLE-US-00004 TABLE 4 Catalyst performance and their correspondent polymers properties of SCB01-PP to SCB08-PP. Activity XS.sup.a mmmm.sup.c % powder.sup.e Polymers (kg/g) (%) MFI MWD.sup.b (mol %) <0.1 mm SCB01-PP 6 8.4 14.3 4.2 90.6 NA SCB02-PP 30 5.7 11.7 3.7 92.5 0.4 SCB03-PP 24 4.8 17.9 4.1 88.8 1.4 SCB04-PP 32 3.6 11.7 3.7 93.1 1.1 SCB05-PP.sup.d NA NA NA NA NA NA SCB06-PP 40 4.1 10.6 6.1 94.0 0.1 SCB07-PP 12 4.5 24.8 7.1 93.0 0.6 SCB08-PP 10 4.3 23.8 7.1 93.1 1.5 .sup.aWet method; .sup.bdetermined with GPC; .sup.cdetermined with .sup.13C NMR; .sup.dSCB05 was not prepared; .sup.esamples with activity below 10 kg of PP/g of catalyst were not measured.