Quantum Chemical Corporation

Other

Equistar Chemicals, LP

Chevron Chemical Company LLC

Albert P Masino

Charles K Buehler

Raghu K Menon

Mark K Reinking

John M Power

Javier M Mora

Woo-Kyu Kim

Klaus H Theopold

Leonard A MacAdams

Douglas D Klendworth

Richard W Fries

William J Sartain

Keta M Lindstrom

Therese A Pastrick

Patricia A Hooks

Stella L Ellis

Buehler: Charles K

Catalyst compounds with &bgr;-diiminate anionic ligands and processes for polymerizing olefins

Catalyst compounds with &bgr;-diminate anionic ligands and processes for polymerizing olefins

A catalyst component formed by the steps of contacting a transition metal-containing metallocene of a transition metal of Group 4, 5 or 6 of the Periodic Table of the Elements with silica or an organic support. This product is contacted with an organomagnesium compound or complex followed by contact with an alcohol and a silane. Finally, the so-contacted product is contacted with a Group 4, 5 or. 6 transition metal-containing non-metallocene compound. The component is preferably combined with an aluminum-containing cocatalyst to form a catalyst system.

Catalyst component and system

A new catalyst useful in the polymerization of at least one olefin is disclosed. The catalyst comprises the product obtained by contacting silica, in random order, with (1) at least one hydrocarbon soluble magnesium-containing compound; and (2) a first modifying compound selected from the group consisting of silicon halides, boron halides, aluminum halides and mixtures thereof followed by a second modifying compound selected from the group consisting of halides having the structural formula SiH.sub.r X.sup.2.sub.s, where X.sup.2 is halogen; r is an integer of 1 to 3; and s is an integer of 1 to 3 with the proviso that the sum of r and s is 4, a hydrogen halide and mixtures thereof. The product of this step is contacted with a first titanium-containing compound having the structural formula Ti(OR).sub.m X.sub.n, where R is hydrocarbyl or cresyl; X is halogen; m is an integer of 1 to 4; and n is 0 or an integer of 1 to 3, with the proviso that the sum of m and n is 4. Finally, the product of this latter step is, in turn, contacted with a second titanium-containing compound, different from the first titanium-containing compound, having the structural formula TiX.sup.1.sub.p (OR.sup.1).sub.q, where X.sup.1 is halogen; R.sup.1 is hydrocarbyl; p is an integer of 1 to 4; and q is 0 or an integer of 1 to 3, with the proviso that the sum of p and q is 4. A catalyst system comprising the above catalyst, an aluminum-containing first cocatalyst and at least one silane second cocatalyst is also set forth. Finally, a process for polymerizing at least one olefin utilizing the catalyst system of this disclosure is taught.

Process for polymerizing propylene using a silica-supported catalyst

The present invention relates to a novel catalyst component for ethylene polymerization comprising vanadium and titanium. Moreover, when the vanadium/titanium containing catalyst of the present invention is employed with an aluminum-containing cocatalyst enhanced activity as well as melt index is obtained. The present invention is directed to a novel halosilane cocatalyst component which, when used in conjunction with an aluminum containing cocatalyst, is effective in increasing the activity of a silica supported titanium/vanadium containing solid catalyst component in the polymerization of ethylene and/or .alpha.-olefins. In addition to the increased catalytic activity, the polymers produced by the present invention exhibit improved melt index values compared with melt index values typically obtained using prior art catalyst systems. Thus, the catalyst system of the instant invention represent an advancement in the art in view of the combination of increased activity, i.e., yield of polymer produced, and physical properties of the polyolefin product. In another aspect of the present invention, a process for polymerizing ethylene and/or .alpha.-olefins is disclosed. In this process at least one olefin is polymerized under olefin polymerization conditions utilizing the catalyst system of the present invention, which includes the solid catalyst component of the present invention, along with the first cocatalyst, an aluminum-containing compound, and the second cocatalyst, a halosilane.

Cocatalyst for vanadium/titanium containing polymerization catalyst

The present invention is directed to a novel halosilane cocatalyst component which, when used in conjunction with an aluminum containing cocatalyst, is effective in increasing the activity of a supported magnesium/titanium containing catalyst in the polymerization of ethylene and .alpha.-olefins. In addition to the increased catalytic activity, the polymers produced by the present invention are characterized as having an unexpected enhancement in the polymer melt index. Thus, the catalyst system of the instant invention represents an advancement in the art in view of the combination of increased activity, i.e., yield of polymer produced, and physical properties of the polyolefin product. In another aspect of the present invention, a process for polymerizing .alpha.-olefins is disclosed. In this process at least one olefin is polymerized under olefin polymerization conditions utilizing the catalyst system of the present invention, which includes the solid catalyst component of the present invention, along with the first cocatalyst, an aluminum-containing compound, and the second cocatalyst, a halosilane compound.

Cocatalyst for transition metal-containing .alpha.-olefin polymerization

The present invention is directed to a novel halosilane cocatalyst component which may be used in conjunction with an aluminum-containing cocatalyst to provide enhanced catalytic activity of a vanadium based solid catalyst component in the polymerization of .alpha.-olefins. In addition to the enhancement in the catalytic activity obtaining using the present catalyst system, the resultant polymer produced by the present invention exhibits improved physical properties compared with polymers produced by prior art vanadium based catalyst systems. Thus, the catalyst system of the instant invention represents an advance in the art in view of the combination of increased catalytic activity, i.e. yield of polymer produced, and enhanced physical properties of the polyolefin produced. In accordance with the present invention, a catalyst system is provided which comprises a solid catalyst component and a halosilane cocatalyst component. The solid catalyst component of the present invention is the product formed by admixing a solid inorganic oxide, an organometallic compound, a vanadium-containing compound and an organic reagent. In another aspect of the present invention, a process of the polymerization of .alpha.-olefins is disclosed. In this process at least one olefin is polymerized under olefin polymerization catalyst utilizing the catalyst system of the present invention, which includes the solid catalyst component of the present invention, and a cocatalyst selected from the group consisting of halosilane compounds and admixtures thereof with aluminum compounds.

Cocatalyst for vanadium-containing ethylene polymerization catalyst

A novel catalyst support and a method for preparation thereof, characterized by the presence of selected amounts of a hydrocarbon soluble magnesium-containing compound applied to the support relative to solvent, wherein a surface uniformly and essentially continuously moistened with the solvated magnesium compound in a condition of incipient precipitation to permit the formation of a regular essentially continuous distribution of the magnesium compound onto and conforming to the support material. The drying process under these conditions is effective in maintaining to a high degree the effective surface area and pore volume of the material. The support containing the adsorbed magnesium is then dried in a controlled manner to essential incipient wetness conditions providing a regular spatial distribution of stacked reticular magnesium values at a level of one to five molecular monolayers on the support. A representative process for polymerizing or copolymerizing olefins providing stereospecific polymers such as propylene is disclosed.

Supported high activity polyolefin catalyst component with regular

A new catalyst component useful in the polymerization of at least one olefin is disclosed. The catalyst component comprises the product obtained by contacting silica, in random order, with (1) at least one hydrocarbon soluble magnesium-containing compound; and (2) a first modifying compound selected from the group consisting of silicon halides, boron halides, aluminum halides and mixtures thereof followed by a second modifying compound selected from the group consisting of halides having the structural formula SiH.sub.r X.sup.2.sub.s, where X.sup.2 is halogen; r is an integer of 1 to 3; and s is an integer of 1 to 3 with the proviso that the sum of r and s is 4, a hydrogen halide and mixtures thereof. The product of this step is contacted with a titanium-containing compound having the structural formula TiX.sup.1.sub.p (OR.sup.1).sub.q, where X.sup.1 is halogen; R.sup.1 is hydrocarbyl; p is an integer of 1 to 4; and q is 0 or an integer of 1 to 3, with the provisos that the sum of p and q is 4 and that a second titanium-containing compound having the structural formula Ti(OR).sub.m X.sub.n, where R is hydrocarbyl; X is halogen; m is an integer of 1 to 4; n is 0 or an integer of 1 to 3; and the sum of m and n is 4, is not utilized in the formation of said catalyst component. A catalyst system comprising the above catalyst component, an aluminum-containing first cocatalyst and at least one silane second cocatalyst is also set forth. Finally, a process for polymerizing at least one olefin utilizing the catalyst system of this disclosure is taught.

Olefin polymerization using silica supported catalyst

A method of polymerizing one or more 1-olefins using a catalyst system incorporating a solid catalyst component is disclosed wherein the catalyst component is prepared by contacting, in the presence of an inert liquid hydrocarbon, silica, a soluble organomagnesium compound, an SiCl.sub.4 magnesium fixing agent, an alcohol, TiCl.sub.4, and a carboxylic acid derivative, followed by extraction with a TiCl.sub.4 containing extraction liquid. The inventive catalyst system allows ready control of product molecular weight by control of hydrogen concentration in the reactor, and allows the production of high MI or MF polymers at high productivities.

Olefin polymerization method

A new catalyst component useful in the polymerization of at least one olefin is disclosed. The catalyst component comprises the product obtained by contracting silica, in random order, with (1) at least one hydrocarbon soluble magnesium-containing compound; and (2) a first modifying compound selected from the group consisting of silicon halides, boron halides, aluminum halides and mixtures thereof followed by a second modifying compound selected from the group consisting of halides having the structural formula SiH.sub.r X.sup.2.sub.s, where X.sup.2 is halogen; r is an integer of 1 to 3; and s is an integer of 1 to 3 with the proviso that the sum of r and s is 4, a hydrogen halide and mixtures thereof. The product of this step is contacted with a titanium-containing compound having the structural formula TiX.sup.1.sub.p (OR.sup.1).sub.q, where X.sup.1 is halogen; R.sup.1 is hydrocarbyl; p is an integer of 1 to 4; and q is 0 or an integer of 1 to 3, with the provisos that the sum of p and q is 4 and that a second titanium-containing compound having the structural formula Ti(OR).sub.m X.sub.n, where R is hydrocarbyl; X is halogen; m is an integer of 1 to 4; n is 0 or an integer of 1 to 3; and the sum of m and n is 4, is not utilized in the formation of said catalyst component. A catalyst system comprising the above catalyst component, an aluminum-containing first cocatalyst and at least one silane second cocatalyst is also set forth. Finally, a process for polymerizing at least one olefin utilizing the catalyst system of this disclosure is taught.

Silica supported polymerization catalyst system

A solid catalyst component, a method of making the same, a catalyst system incorporating the solid catalyst component, and a method of polymerizing one or more 1-olefins using the catalyst system are disclosed wherein the catalyst component is prepared by contacting, in the presence of an inert liquid hydrocarbon, silica, a soluble organomagnesium compound, an SiCl.sub.4 magnesium fixing agent, an alcohol, TiCl.sub.4, a carboxylic acid derivative, followed by extraction with a TiCl.sub.4 -containing extraction liquid. The inventive catalyst system allows ready control of product molecular weight by control of hydrogen concentration in the reactor, and allows the production of high MI or MF polymers at high productivities.

Olefin polymerization catalyst and methods

A new catalyst useful in the polymerization of at least one olefin is disclosed. The catalyst comprises the product obtained by contacting silica, in random order, with (1) at least one hydrocarbon soluble magnesium-containing compound; and (2) a first modifying compound selected from the group consisting of silicon halides, boron halides, aluminum halides and mixtures thereof followed by a second modifying compound selected from the group consisting of halides having the structural formula SiH.sub.r X.sup.2.sub.s, where X.sup.2 is halogen; r is an integer of 1 to 3; and s is an integer of 1 to 3 with the proviso that the sum of r and s is 4, a hydrogen halide and mixtures thereof. The product of this step is contacted with a first titanium-containing compound having the structural formula Ti(OR).sub.m X.sub.n, where R is hydrocarbyl or cresyl; X is halogen; m is an integer of 1 to 4; and n is 0 or an integer of 1 to 3, with the proviso that the sum of m and n is 4. Finally, the product of this latter step is, in turn, contacted with a second titanium-containing compound, different from the first titanium-containing compound, having the structural formula TiX.sup.1.sub.p (OR).sup.1).sub.q, where X.sup.1 is halogen; R.sup.1 is hydrocarbyl; p is an integer of 1 to 4; and q is 0 or an integer of 1 to 3, with the proviso that the sum of p and q is 4. A catalyst system comprising the above catalyst, an aluminum-containing first cocatalyst and at least one silane second cocatalyst is also set forth. Finally, a process for polymerizing at least one olefin utilizing the catalyst system of this disclosure is taught.

Growing community of inventors

Hamilton, OH, United States of America

Albert P Masino