Methods for producing bimodal polyolefins and impact copolymers

Abstract

Provided are methods for producing bimodal polyolefins comprising the steps of contacting α-olefin monomers with a catalyst in slurry polymerization conditions in the presence of zero to minimum hydrogen to produce a high molecular weight polyolefin and contacting additional α-olefin monomers in gas phase polymerization conditions and the high molecular weight polyolefin and the catalyst to produce bimodal polyolefin having high stiffness and broad molecular weight distribution. An additional step of polymerizing the bimodal polyolefin with a comonomer in a second gas phase can provide a bimodal impact copolymer having high stiffness and broad molecular weight distribution. Among the advantages of the present methods, bimodal polyolefins can be produced in a continuous process between a slurry polymerization reactor and a gas phase polymerization reactor without a venting step in between and with minimal hydrogen in the slurry polymerization reactor.