Union Carbide Chemicals & Plastics Technology Corporation

Union Carbide Corporation

Robert Charles Job

Robert J Jorgensen

Burkhard Eric Wagner

Walter Thomas Reichle

Ann M Schoeb-Wolters

William James Michie, Jr

William A Hoffman, Iii

Vinayak Maheshwari

Methods of preparing a polymerization catalyst component is provided, in which a magnesium component, a Lewis acid solubilizing component, a titanium compound, optionally a transition metal compound different than the titanium compound, and typically an inert filler are combined in a slurrying agent and spray-dried to produce a catalyst precursor in the form of a substantially spherical and porous solid particle. The methods and catalysts of this disclosure can provide ethylene homopolymer and copolymer resins having a high molecular weight tail and a broadened molecular weight distribution as compared to more traditional Ziegler-Natta catalysts.

Ziegler-natta catalyst compositions for producing polyethylenes with a high molecular weight tail and methods of making the same

A solid, hydrocarbon insoluble catalyst composition comprising: A) a solid, particulated complex comprising moieties of at least magnesium, a Group 4 transition metal, and a halide; B) one or more &#x3b1;-amino-substituted- or &#x3b1;-imino-substituted-2-alkylpyridine compounds; C) one or more organoaluminum cocatalyst compounds; D) optionally one or more internal electron donors; and E) optionally one or more selectivity control agents, a method of preparation and a method of use in polymerizing olefins is disclosed.

Mixed catalyst compositions for the production of polyolefins

A process for making a solid composition comprising alkoxide groups, chloride groups, one or more metals, M, in the &plus;2 oxidation state selected from Mg, Ca, Mn, Cu, Co or Zn, and one or more metals, T, in the &plus;3, &plus;4 or &plus;5 oxidation state selected from Ti, Zr, V, Sm, Fe, Ni, Rh, Co, Cr, Mo, W or Hf, the molar ratio M/T of the composition being from 2.5 to 3.75, said process comprising contacting one or more alkoxide containing compounds of metal M, one or more alkoxide compounds of metal T, and a halide compound, the molar ratio M/T of the contacting compounds being from 2.5 to 3.5, and recovering the resulting solid.

Mixed metal alkoxide complexes and polymerization catalysts made therefrom

A method of halogenating a precursor to form a polymerization procatalyst is disclosed whereby a magnesium/transition metal-containing alkoxide complex precursor is contacted with a halogenating agent selected from alkylaluminum halide, TiX , SiX , BX , and Br , where halide and X are reach respectively a halogen, and when an alkylaluminum halide, TiX , SiX , BX , and Br are used as the halogenating agent, they are used together or in combination in a multi-step halogenation. The procatalyst then can be converted to an olefin polymerization catalyst by contacting it with a cocatalyst and optionally a selectivity control agent, and used to polymerize olefins in high yield with desired properties.

Methods of making magnesium/transition metal alkoxide complexes and polymerization catalysts made therefrom

A solid self-supported cycloalkadienyl catalyst component is disclosed that includes: (i) a mixed metal alkoxide complex which is the reaction product of a magnesium alkoxide or aryloxide and at least one group IVB metal-containing alkoxide or aryloxide; and (ii) Cp, where Cp is a cyclic or polycyclic hydrocarbon having from 3-30 carbon atoms. A self-supported hybrid catalyst also is disclosed which contains the above components (i) and (ii), as well as (iii) a Ziegler-Natta catalyst species. A method of making the self-supported cycloalkadienyl catalyst and the self-supported hybrid catalyst and a method of polymerizing olefins using the catalysts also are disclosed. The catalysts are capable of producing polyolefins in high yield having a broad molecular weight distribution, or a bimodal distribution.

Mixed metal alkoxide and cycloalkadienyl catalysts for the production of polyolefins

A solid self-supported hybrid catalyst is disclosed which contains (i) a Ziegler-Natta catalyst component including at least one group IVB metal-containing alkoxide or aryloxide; and (ii) Cp, where Cp is a cycloalkadienyl hydrocarbon having from 3-30 carbon atoms. A method of making the self-supported hybrid catalyst and a method of polymerizing olefins using the catalysts also are disclosed. The catalysts are capable of producing polyolefins in high yield having a broad molecular weight distribution, or a bimodal molecular weight distribution.

Hybrid ziegler-natta and cycloalkadienyl catalysts for the production of polyolefins

A process for production of a polyethylene blend in situ comprising contacting ethylene and at least one alpha-olefin with a magnesium/titanium based catalyst system including a partially activated precursor and a cocatalyst in each of two fluidized bed reactors connected in series, one of the provisos being that the precursor is formed by contacting an alkylaluminum halide with a solid reaction product prepared from a magnesium alkoxide, a titanium tetraalkoxide, and a solubility enhancing agent.

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Bound Brook, NJ, United States of America

Robert Charles Job