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  Magnesium compound, solid catalyst component, olefin polymerization catalyst, and method for producing polyolefinUSPTO Application #: 20070213206Title: Magnesium compound, solid catalyst component, olefin polymerization catalyst, and method for producing polyolefin Abstract: where Et is an ethyl group, Me is a methyl group and n is a numerical value of from 0.001 to 1. Mg(OEt)2-n(OMe)n (I) A magnesium compound represented by the formula (I) which is obtained by reacting metal magnesium, ethanol, methanol and a halogen and/or a halogen-containing compound containing at least 0.0001 gram atom of a halogen atom relative to one gram atom of the metal magnesium (end of abstract) Agent: Oblon, Spivak, Mcclelland, Maier & Neustadt, P.C. - Alexandria, VA, US Inventors: Shojiro Tanase, Nobuhiro Yabunouchi, Takanori Sadashima USPTO Applicaton #: 20070213206 - Class: 502171000 (USPTO) Related Patent Categories: Catalyst, Solid Sorbent, Or Support Therefor: Product Or Process Of Making, Catalyst Or Precursor Therefor, Organic Compound Containing, Organic Compound Contains Metal (e.g., Na-o-ethyl, Etc.) The Patent Description & Claims data below is from USPTO Patent Application 20070213206. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] The invention relates to a magnesium compound which is useful for homopolymerization or copolymerization of an .alpha.-olefin such as ethylene and propylene, a solid catalyst component using the magnesium compound, a catalyst for olefin polymerization and a method of producing an olefin polymer. TECHNICAL BACKGROUND [0002] Hitherto, magnesium chloride and magnesium alkoxides have been widely used as a support material without being milled in the field of catalysts for olefin polymerization, specifically the homopolymerization or copolymerization of .alpha.-olefin such as ethylene and propylene. This may improve the catalyst activity and the morphology of polymer powder. [0003] For example, for improving an obtained polymer in morphology including particle size, form, etc., there are known a method in which a magnesium compound is supported on an inorganic oxide such as silica (JP-A-S63-280707) and a method in which a magnesium compound once dissolved in a solvent such as an alcohol is precipitated again and the precipitate is used (JP-A-S58-000811). However, these methods include very complicated steps, since they require the procedures of supporting, dissolving and precipitating a magnesium compound. Further, these methods have a defect in that the catalyst is poor in performance stability. [0004] The method of using as a support of catalysts a magnesium compound obtained by reacting metal magnesium, an alcohol such as ethanol and a certain amount of halogen (JP-A-H4-130107) has been developed. However, it has a problem in the point that the catalyst activity and the apparent density of the polymer powder obtained depends on the conditions. [0005] In order to improve a polymerization activity and an appearance of film in ethylene polymerization, the method of using a support such as magnesium alkoxide pulverized mechanically (JP-A-H9-194522) has been disclosed. [0006] However, the pulverization of a support causes increase in amount of fine powder contained in polymer powder, which reflects the properties of support particles, and bad powder form. A converting line may be blocked due to the increase in amount of fine powder. The flowability of powder may be lowered due to the bad powder form, thereby letting reactor operation unstable Further the polymerization activity and controllability of molecular weight may be unsatisfactory. [0007] In view of the above-mentioned problems, a purpose of the invention is to provide a magnesium compound which exhibits high activity without decrease of performances such as stereoregularity and appearance of film (fish-eye), are excellent in control of molecular weight and can give an olefin polymer excellent in apparent density; a solid catalyst component; a catalyst for olefin polymerization; and a method of producing an olefin polymer. DISCLOSURE OF THE INVENTION [0008] The inventors made efforts to attain the above-mentioned purposes, as the result, they found that the specific magnesium compound obtained by reacting a metal magnesium, ethanol, methanol and a halogen and/or a halogen-containing compound containing a predetermined amount of halogen atom as essential components is useful as a catalyst component. They also found that a catalyst for olefin polymerization comprising a solid catalyst component obtained by contacting the magnesium compounds a titanium compound, and, if necessary, a halide, an electron donating compound and an alcohol, an organometallic compound and an optional electron donating compound exhibits high activity, is excellent in control of molecular weight and can give an olefin polymer excellent in apparent density. The invention has been made based on the above findings. [0009] The invention provides the following magnesium compound, solid catalyst component, catalyst for olefin polymerization and method of producing olefin polymer. [0010] 1. A magnesium compound represented by the formula (I) which is obtained by reacting metal magnesium, ethanol, methanol and a halogen and/or a halogen-containing compound containing at least 0.0001 gram atom of a halogen atom relative to one gram atom of the metal magnesiumMg(OEt).sub.2-n(OMe).sub.n (I) [0011] where Et is an ethyl group, Me is a methyl group and n is a numerical value of from 0.001 to 1. [0012] 2. The magnesium compound according to 1, which has an average particle diameter D.sub.50 of from 4 to 20 .mu.m and a particle size distribution index (P) represented by the general formula (1) of P<4.0P=(D.sub.90/D.sub.10) (1) [0013] where D.sub.90 is a particle diameter corresponding to 90% of cumulative weight fraction, and D.sub.10 is a particle diameter corresponding to 10% of cumulative weight fraction. [0014] 3. The magnesium compound according to 1 or 2, wherein the halogen is iodine. [0015] 4 The magnesium compound according to 1 or 2, wherein the halogen-containing compound is magnesium dichloride. [0016] 5. The magnesium compound according to any one of 1 to 4, wherein n of the formula (I) is a numerical value of from 0.01 to 0.2. [0017] 6. A solid catalyst component obtained by reacting the following components (a) and (b): [0018] (a) the magnesium compound according to any one of 1 to 5 [0019] (b) a titanium compound represented by the formula (II)Ti(OR).sub.qX.sub.4-q (II) [0020] where X is a halogen atom, R is a hydrocarbon group having from 1 to 10 carbon atoms, q is an integer of from 0 to 4, and a plurality of R's are the same as or different from each other when q is 2 or more. [0021] 7. The solid catalyst component according to claim 6 obtained by reacting a halogen compound (c) and/or an electron donating compound (d) in addition to the components (a) and (b). [0022] 8 The solid catalyst component according to 6 obtained by reacting a halogen compound(c) and/or an alcohol (e) in addition to the components (a) and (b). [0023] 9 The solid catalyst component according to 7 or 8 wherein the halogen compound (c) is silicon tetrachloride. [0024] 10, The solid catalyst component for ethylene polymerization according to 8, wherein the alcohol (e) is isopropanol. [0025] 11. A catalyst for olefin polymerization comprising the following components (A) and (B): [0026] (A) the solid catalyst component according to any one of 6 to 10 [0027] (B) an organometallic compound. [0028] 12. The catalyst for olefin polymerization according to 11 further comprising an electron donating compound (C). [0029] 13. A method of producing a polyolefin using the catalyst for olefin polymerization according to 11 or 12. [0030] There can be produced an ethylene-based polymer that exhibits high polymerization activity, excellent controllability of molecular weight and high stereoregularity by using a catalyst for olefin polymerization using the magnesium compound of the invention. There can also be produced a polymer excellent in apparent density and morphology. BRIEF DESCRIPTION OF THE DRAWINGS [0031] FIG. 1 is a drawing which shows the olefin-polymerization catalyst system of the invention. BEST MODE FOR CARRYING OUT THE INVENTION [0032] FIG. 1 is a drawing which shows the olefin polymerization catalyst system including the magnesium compound of the invention. Now the magnesium compound, the solid catalyst component and the catalyst for olefin polymerization will be explained. [Magnesium Compound] [0033] Firstly, the magnesium compound of the invention will be specifically explained. [0034] The magnesium compound of the invention represented by the formula (I) which is obtained by reacting metal magnesium, ethanol, methanol and a halogen and/or a halogen-containing compound containing at least 0.0001 gram atom of a halogen atom relative to one gram atom of the metal magnesiumMg(OEt).sub.2-n(OMe).sub.n (I) where Et is an ethyl group, Me is a methyl group and n is a numerical value of from 0.001 to 1. [0035] The form and the like of the metal magnesium are not particularly limited. The surface state of the metal magnesium is not also particularly limited but metal magnesium without a coating of magnesium hydroxide or the like on the surface thereof is preferred. [0036] Although the purity and water content of ethanol and methanol, which both ethanol and methanol may be hereinafter abbreviated to alcohol, are not particularly limited, when using an alcohol having high water content, magnesium hydroxide may be formed on the surface of the metal magnesium. Thus an alcohol having a water content of 1% or below, particularly 2,000 ppm or below, is preferably used. Further, morphology improves with decreasing water content, so that an alcohol having a water content of 200 ppm or below is generally preferably. [0037] Although the kind of the halogen is not particularly limited, chlorine, bromine or iodine is preferably used. Iodine is particularly preferably used. [0038] The kind of the halogen-containing compound is not limited, and any compound containing a halogen atom may be used. Although the kind of the halogen atom is not particularly limited, chlorine, bromine or iodine is preferred. Among the halogen-containing compounds, halogen-containing metal compounds are particularly preferred. Continue reading... Full patent description for Magnesium compound, solid catalyst component, olefin polymerization catalyst, and method for producing polyolefin Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Magnesium compound, solid catalyst component, olefin polymerization catalyst, and method for producing polyolefin patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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