Exxonmobil Chemical Patents Inc.

Todd S Edwards

Christopher Garland Bauch

Prasadarao Meka

Chon-Yie Lin

Kevin Wayne Lawson

Blu E Englehorn

Lubin Luo

Jeffrey Lawrence Brinen

George James Pehlert

Saifudin M Abubakar

Keith W Trapp

Daniel L Bilbao

Yumin Chen

Xiaodan Zhang

Sung A Kim

Shirley Yumin Chen

Provided herein are methods of polymerizing α-olefin monomer with a catalyst and hydrogen in a slurry to produce low molecular weight polyolefins. Hydrogen is vented from the low molecular weight polyolefins and then the low molecular weight polyolefins are further polymerized in a gas phase to produce a polyolefin having a molecular weight distribution of between 4.0 and 30 and a flexural modulus between 1500 mPa and 2500 mPa.

Processes for producing polyolefins and impact copolymers with broad molecular weight distribution and high stiffness

Disclosed is a polypropylene with an MFR of at least 20 g/10 min comprising a homopolypropylene and optionally within a range from 2 wt % to 30 wt % of an propylene-&#x3b1;-olefin copolymer by weight of the polypropylene; wherein the homopolypropylene has a MFR within a range from 30 g/10 min to 200 g/10 min, an Mw/Mn within a range from 7 to 16, and comprising 1.1 wt % or less atactic polypropylene based on the total weight of the homopolypropylene and atactic polypropylene, where the propylene-&#x3b1;-olefin copolymer has within a range from 30 wt % to 50 wt % &#x3b1;-olefin derived units by weight of the propylene-&#x3b1;-olefin copolymer, and an intrinsic viscosity within a range from 4 to 8 dL/g. The impact copolymer may be obtained by combining a Ziegler-Natta catalyst having at least two different internal electron donors with propylene in reactors in series to produce the homopolypropylene followed by a gas phase reactor to produce a propylene-&#x3b1;-olefin copolymer.

High stiffness polypropylene impact copolymer

Disclosed is a polypropylene with an MFR of at least 20 g/10 min comprising a homopolypropylene and within a range from 2 wt % to 20 wt % of a propylene-&#x3b1;-olefin copolymer by weight of the polypropylene, where the homopolypropylene has a MFR within a range from 30 g/10 min to 200 g/10 min, where the propylene-&#x3b1;-olefin copolymer comprises within a range from 30 wt % to 50 wt % &#x3b1;-olefin derived units by weight of the propylene-&#x3b1;-olefin copolymer, and has an IV within a range from 4 to 9 dL/g. The polypropylene may be obtained by combining a Ziegler-Natta catalyst having two transition metals with propylene in reactors in series to produce the homopolypropylene followed by a gas phase reactor to produce a propylene-&#x3b1;-olefin copolymer blended with the homopolypropylene.

High impact polypropylene impact copolymer

A process for reducing the level of hydrogen in certain polymerization effluent and recycle streams containing unreacted propylene monomers and hydrogen by contacting the streams with a hydrogenation catalyst so as to convert at least part of the propylene to the corresponding alkane. The process is particularly applicable to the effluent from a slurry polymerization reactor which has been used to produce a polypropylene homopolymer or copolymer having a first molecular weight and at least part of the effluent is to be supplied to a slurry polymerization reactor to produce a polypropylene homopolymer or copolymer having a second, higher molecular weight.

Olefin polymerization processes

Disclosed is a method of reducing and/or regulating the level of hydrogen in a polymerization reactor comprising contacting a first feed comprising a first amount of hydrogen with a hydrogenation catalyst prior to entering a polymerization reactor to form a second feed; then contacting the second feed having a second amount of hydrogen with monomers and a polymerization catalyst in a polymerization reactor to form a polymer. The first and second feeds may reside in a feed line from one reactor to another, a monomer feed line to the reactor, or in a recycle line to and from the same reactor.

Method of regulating hydrogen to a polymerization reactor

A propylene-based impact copolymer having a high gloss and suitable for appliance components comprising a polypropylene homopolymer and within a range of from 6 wt % to 20 wt % of propylene copolymer based on the weight of the impact copolymer, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, and/or C4 to C10 &#x3b1;-olefin derived units and the remainder propylene-derived units based on the weight of the propylene copolymer, the impact copolymer having a melt flow rate (230&#xb0; C./2.16 kg) within a range of from 10 g/10 min to 50 g/10 min.

Low comonomer propylene-based impact copolymers

A propylene-based impact copolymer (ICP) and composition including the ICP, the ICP comprising a polypropylene homopolymer and within the range of from 10 wt % to 45 wt % of propylene copolymer based on the weight of the ICP, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, 1-butene, 1-hexene and/or 1-octene derived units and from 80 to 60 wt % propylene-derived units based on the weight of the propylene copolymer, the propylene-based impact copolymer having a Melt Flow Rate (230&#xb0; C./2.16 kg) within the range of from 10 g/10 mm to 50 g/10 mm and an Elongation at Break of greater than 70%.

Propylene-based impact copolymers

A method is provided for polymerizing an olefin monomer in a reactor with a highly active polyolefin polymerization catalyst system. The method includes introducing a catalyst system comprising a catalyst and a catalyst activator into the reactor containing the olefin monomer with less than 10 seconds or no pre-contacting time of the catalyst and the catalyst activator prior to introducing the catalyst and the catalyst activator into the reactor. The catalyst system may have a standard adjusted catalyst activity of greater than 10 gPgcathr.

Methods for polyolefin polymerization with high activity catalyst systems

Polypropylene resin comprising at least 50 mol % propylene, an MWD (Mw/Mn) of greater than 5, a branching index (g') of at least 0.95, and a melt strength of at least 20 cN determined using an extensional rheometer at 190&#xb0; C. A catalyst system comprising a Ziegler-Natta catalyst comprising a non-aromatic internal electron donor, and first and second external electron donors comprising different organosilicon compounds, and a method to produce a polypropylene resin comprising contacting propylene monomers at propylene polymerization conditions with the catalyst system are also disclosed.

Broad molecular weight distribution polypropylene resins

A propylene-based impact copolymer (ICP) and composition including the ICP, the ICP comprising a polypropylene homopolymer and within the range of from 10 wt % to 45 wt % of propylene copolymer based on the weight of the ICP, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, 1-butene, 1-hexene and/or 1-octene derived units and from 80 to 56 wt % propylene-derived units based on the weight of the propylene copolymer, the propylene-based impact copolymer having a Melt Flow Rate (230&#xb0; C./2.16 kg) within the range of from 10 g/10 min to 50 g/10 min and an Elongation at Break of greater than 70%.

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League City, TX, United States of America

Todd S Edwards