Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07F—ACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
  • C07F17/00—Metallocenes
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/02—Ethene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/04—Monomers containing three or four carbon atoms
  • C08F110/06—Propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65916—Component covered by group C08F4/64 containing a transition metal-carbon bond supported on a carrier, e.g. silica, MgCl2, polymer

Definitions

• This invention relates to catalysts for olefin 5 polymerisation, in particular to catalyst compounds containing metals ⁇ -bonded by siloxycyclopentadienyl ligands, and their use in olefin polymerisation.
• metal is here meant an ⁇ -ligand metal complex, e.g. an "open sandwich” or “half sandwich” compound in which the metal is complexed by a single ⁇ - ligand, a “sandwich” compound in which the metal is 15 complexed by two or more ⁇ -ligands, a "handcuff” compound” in which the metal is complexed by a bridged bis- ⁇ -ligand or a “scorpionate” compound in which the metal is complexed by an ⁇ -ligand linked by a bridge to a ⁇ -ligand.
• ⁇ -ligand metal complex e.g. an "open sandwich” or “half sandwich” compound in which the metal is complexed by a single ⁇ - ligand, a “sandwich” compound in which the metal is 15 complexed by two or more ⁇ -ligands, a "handcuff” compound” in which the metal is complexed by a bridged bis- ⁇ -ligand or a "scorpionate”
• Alumoxanes are compounds with alternating aluminium and oxygen atoms generally compounds of formula I or II
• each R which may be the same or different, is a i-i o alkyl group, and p is an integer having a value between 0 and 40) .
• alumoxanes 30 reaction of an aluminium alkyl with water.
• the production and use of alumoxanes is described in the patent literature, especially the patent applications of Texas Alkyls, Albemarle, Ethyl, Phillips, Akzo Nobel, Exxon, Idemitsu Kosan, Witco, BASF and Mitsui. - - 35
• the most widely used alumoxane is methylalumoxane (MAO) , an alumoxane compound in which the R groups are methyls.
• MAO methylalumoxane
• MAO is poorly 2characterised and relatively expensive and efforts have been made to use alumoxanes other than MAO.
• 098/32775 proposes the use of metallocene procatalysts with alumoxanes in which R is a C 2 _ 10 alkyl group, eg hexaisobutylalumoxane (HIBAO) .
• R is a C 2 _ 10 alkyl group, eg hexaisobutylalumoxane (HIBAO) .
• metallocenes in which the metal is ⁇ -liganded by a siloxy-, homo or heterocyclic cyclopentadienyl group i.e. a cyclic ⁇ 5 -ligand substituted by a siloxy group but not carrying a fused ring, have surprisingly high activity with non- MAO alumoxanes .
• the invention provides a metallocene procatalyst compound comprising a group 3 to 7 transition metal ⁇ -liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group .
• group 3 (etc) metal is meant a metal in group 3 of the Periodic Table of the Elements, namely Sc, Y, etc .
• the invention provides an olefin polymerisation catalyst system comprising or produced by reaction of (i) a metallocene procatalyst compound comprising a group 3 to 7 transition metal ⁇ - liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group and (ii) a co- catalyst, eg an aluminium alkyl compound, in particular an alumoxane, especially an aluminium alkyl compound comprising alkyl groups containing at least two carbon atoms .
• a metallocene procatalyst compound comprising a group 3 to 7 transition metal ⁇ - liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group
• a co- catalyst eg an aluminium alkyl compound, in particular an alumoxane, especially an aluminium alkyl compound comprising alkyl groups containing at least two carbon
• the invention provides a process for olefin polymerisation comprising polymerising an olefin in the presence of a metallocene compound comprising a group 3 to 7 transition metal ⁇ - liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
• a metallocene compound comprising a group 3 to 7 transition metal ⁇ - liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
• the invention provides a process for the preparation of a metallocene procatalyst, said process comprising metallating with a group 3 to 7 transition metal a ligand comprising a siloxy-substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
• the invention provides the use of a metallocene compound comprising a group 3 to 7 transition metal ⁇ -liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group in olefin polymerization, especially ethylene or propylene, more especially ethylene, polymerisation or copolymerisation.
• the invention provides an olefin polymer produced by a polymerisation catalysed by a metallocene compound comprising a group 3 to 7 transition metal ⁇ -liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
• a metallocene compound comprising a group 3 to 7 transition metal ⁇ -liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
• monocyclic it is meant that the ⁇ 5 ring of the cyclopentadienyl group is not fused to another ring, ie it cannot be a part of an indenyl or fluorenyl multi- ring structure.
• the ⁇ 5 ring however may be substituted by cyclic groups or cyclic group containing substituents and the metal may be liganded by other ⁇ -ligands which are acyclic or multicyclic.
• the ⁇ 5 -ligand with which the group 3 to 7 metal is complexed typically is a compound of formula IV
• each R' which may be the same or different is a R + , OR + , SR + , NR + 2 or PR + 2 group where each R + is a C ⁇ .
• each R' being a C ⁇ 12 hydrocarbyl group, eg a C ⁇ _ 8 alkyl or alkenyl group; each R", which may be the same or different is a ring substituent which does not form a bond to a metal ⁇ -bonded by the C 2 XYT ring and is other than a ring fused to the C 2 XYT ring, eg it may be a R + , OR + , SR + , NR + 2 or PR + 2 group where each R + is a C x _ 16 nydrocarbyl group, a hydrocarbylsilyl group or a group; n is zero or a positive integer, eg having a value of 1, 2, 3 or 4, n preferably being non-zero; m is zero or 1, at least one of n and m preferably being non zero; and
• R"' is an ⁇ -ligand linked to the C 2 XYT ring by a 1 to 3 atom bridge, and optionally substituted, eg by R" groups .
• the group 3 to 7 transition metal may be ⁇ -liganded by one or two further ⁇ ligands. These may be cyclic or acyclic and may carry cyclic groups fused to an ⁇ 5 or ⁇ 4 cyclic or acyclic structure and may be bridged bis- ⁇ ("handcuff") ligands or bridged ⁇ - ⁇ ("scorpion") ligands.
• such an ⁇ 5 or ⁇ 4 ligand group may be a homo- or heterocyclic cyclopentadienyl, indenyl or fluorenyl group, or an acyclic ⁇ 5 C 5 , ⁇ 5 -C 3 N 2 or ⁇ 4 C 2 N 2 group optionally carrying cyclic groups fused to the ⁇ 5 or ⁇ 4 skeleton.
• Such further ⁇ ligands may optionally be substituted, eg by groups R" .
• Such further ⁇ -ligands include cyclopentadienyl, indenyl and fluorenyl ligands, especially siloxy substituted (eg ' 3 SiO-substituted) cyclopentadienyl or indenyl ligands.
• the group 3 to 7 metal in the procatalyst of the invention may be coordinated by hydrogen atoms, hydrocarbyl ⁇ -ligands (eg optionally substituted C 1 _ 12 hydrocarbyl groups, such as C 1 _ 12 alkyl, alkenyl or alkynyl groups optionally substituted by fluorine and/or aryl (eg phenyl) groups) , by silane groups (eg Si(CH 3 ) 3 ), by halogen atoms (eg chlorine), by C ⁇ .
• hydrocarbyl ⁇ -ligands eg optionally substituted C 1 _ 12 hydrocarbyl groups, such as C 1 _ 12 alkyl, alkenyl or alkynyl groups optionally substituted by fluorine and/or aryl (eg phenyl) groups
• silane groups eg Si(CH 3 ) 3
• halogen atoms eg chlorine
• amine eg N(CH 3 ) 2
• a ⁇ -ligand moiety is meant a group bonded to the metal at one or more places via a single atom, eg a hydrogen, halogen, silicon, carbon, oxygen, sulphur or nitrogen atom.
• the metallocene pro catalyst of the invention may conveniently be a compound of formula
• X, Y, T, R', R", R"', n and m are as defined above; q is 1, 2 or 3, generally being 1 when m is 1; M is a group 3 to 7 transition metal L is a further ⁇ -ligand (eg as discussed above) ; r is zero, 1 or 2 ;
• Z is a ⁇ -ligand (eg as discussed above) ; and s is zero or a positive integer having a value of up to 3 depending on the values of m, q and r and the oxidation state of metal M.
• the metal M in the metallocene procatalysts of the invention is a group 3 to 7 transition metal, preferably a group 4 to 6 transition metal, eg a metal selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W.
• the metal is preferably Cr, Ti, Zr or Hf, particularly Cr if M is ⁇ -liganded by a single ⁇ -ligand group or Ti, Zr or Hf if M is ⁇ -liganded by one or more ⁇ -ligand groups
• the siloxycyclopentadienyl ⁇ -ligand is especially preferably a ligand of formula VI
• R' is as defined above; Y' is P, B, CH or C-CH 3 ; R* is H or CH 3 ; and R"" is H, CH 3 or Bg-ETA where Bg is a one or two atom bridge (particularly a (CH 2 ) 2 or Si(CH 3 ) 2 bridge) and ETA is a cyclopentadienyl, indenyl, tetrahydroindenyl , fluorenyl , tetrahydrofluorenyl or octahydrofluorenyl or other closed ring ⁇ -ligand group.
• the ETA ligand may be substituted or unsubstituted and the ⁇ 5 ring may be the homo or heterocyclic, eg incorporating P, B or N ring heteroatoms .
• suitable R' 3 SiO groups in the metallocene procatalysts of the invention include
• Typical examples of the metallocene procatalysts of the invention thus include:
• each R'* which may be the same or different, is an up to C 12 hydrocarbyl, e.g. a aromatic or aliphatic hydrocarbyl; each R** which may be the same or different, is H or CH 3 ; each X is CH, CCH 3 , P or B; each Y is CH if X is P or B or is CR** if X is CH or CCH 3 ; and R' is as hereinbefore defined.
• siloxy- ⁇ -ligands examples include:
• EP-B-129368 (Exxon) and EP-B-206724 (Exxon) . These include
• cyclopentadienyl indenyl , fluorenyl , octahydrofluorenyl , methylcyclopentadienyl , 1, 2-dimethylcyclopentadienyl, penta ethylcyclopentadienyl , pentyl-cyclopentadienyl,
• ⁇ -ligands examples include:
• halogenides e.g. chloride and fluoride
• hydrogen triC 1 _ 12 hydrocarbyl-silyl or -siloxy (e.g. trimethylsilyl)
• triC. 6 hydrocarbylphosphimido e.g. triisopropylphosphimido
• c ⁇ - ⁇ 2 hydrocarbyl or hydrocarbyloxy e.g. methyl, ethyl, phenyl , benzyl and methoxy
• diCi.g hydrocarbylamido e.g. dimethylamido and diethylamido
• diCi.g hydrocarbylamido e.g. dimethylamido and diethylamido
• ring membered heterocyclyl eg pyrrolyl, furanyl and pyrrolidinyl
• the siloxy cyclopentadienyl ⁇ -ligands used according to the invention may be prepared by reaction of a corresponding siloxycyclopentadiene with an appropriate base, e.g. an organolithium compound, such as methyllithium or butyllithium.
• an appropriate base e.g. an organolithium compound, such as methyllithium or butyllithium.
• bases of use in this regard include t-BuLi, n-BuLi, lithium diisopropylamide, t-BuOK, trialkylamines, dialkyl- magnesium, alkylmagnesium chloride, alkyl CuLi and dialkyl zinc which may be used in conjunction with a suitable solvent.
• a donor such as dimethoxyethane may be added to the reaction medium containing the siloxycyclopentadiene prior to addition of the base.
• the ligand can be metallated conventionally, eg by reaction with a halide of the metal M, preferably in an organic solvent, eg a hydrocarbon or a hydrocarbon/ether mixture.
• Bridged siloxy-cyclopentadienyl ligands may be constructed by reacting a siloxy-monocyclopentadienyl ligand with a bridging agent (eg Si(CH 3 ) 2 Cl 2 ) or with a bridging agent and a further ⁇ -ligand (eg a different cyclopentadienyl ligand or with an indenyl, fluorenyl, etc ligand) .
• a bridging agent eg Si(CH 3 ) 2 Cl 2
• a further ⁇ -ligand eg a different cyclopentadienyl ligand or with an indenyl, fluorenyl, etc ligand
• siloxycyclopentadiene is reacted with Zr(NMe 2 ) 4 or Zr(CH 2 Ph) 4 followed by Me 3 SiCl to yield the complex directly.
• trimethylsilyl (siloxy) cyclopentadiene reacts with ZrCl 4 to afford the complex directly.
• ⁇ -ligands other than chlorine may be introduced by displacement of chlorine from an ⁇ -ligand metal chloride by reaction with appropriate nucleophilic reagent (e.g.
• a reagent such as tetrakisdimethylamidotitanium or metal compounds with mixed chloro and dimethylamido ligands.
• the olefin polymerisation catalyst system of the invention comprises (i) a siloxycyclopentadienyl metallocene and (ii) an aluminium alkyl compound, or the reaction product thereof.
• the aluminium alkyl compound may be an aluminium trialkyl (eg triethylaluminium (TEA) ) or an aluminium dialkyl halide (eg diethyl aluminium chloride (DEAC) )
• TEA triethylaluminium
• DEAC aluminium dialkyl halide
• it is preferably an alumoxane, particularly an alumoxane other than MAO, most preferably an isobutylalumoxane, eg TIBAO (tetraisobutylalumoxane) or HIBAO (hexaisobutylalumoxane) .
• alkylated (eg methylated) metallocene procatalysts of the invention may be used with other cocatalysts , eg boron compounds such as B (C 6 F 5 ) 3 , C 6 H 5 N (CH 3 ) 2 H : B (C 6 F 5 ) 4 , (C 6 H 5 ) 3 C : B (C 6 F 5 ) 4 or Ni (CN) 4 [B (C 6 F 5 ) 3 ] 4 2 - .
• boron compounds such as B (C 6 F 5 ) 3 , C 6 H 5 N (CH 3 ) 2 H : B (C 6 F 5 ) 4 , (C 6 H 5 ) 3 C : B (C 6 F 5 ) 4 or Ni (CN) 4 [B (C 6 F 5 ) 3 ] 4 2 - .
• the metallocene procatalyst and cocatalyst may be introduced into the polymerization reactor separately or together or, more preferably they are pre-reacted and their reaction product is introduced into the polymerization reactor. If desired the procatalyst, procatalyst/cocatalyst mixture or a procatalyst/cocatalyst reaction product may be used in unsupported form, i.e. metallocene and MAO can be precipitated without an actual carrier material and used as such. However the metallocene procatalyst or its reaction product with the cocatalyst is preferably introduced into the polymerization reactor in supported form, eg impregnated into a porous particulate support .
• the particulate support material used is preferably an organic or inorganic material, e.g. a polymer (such as for example polyethylene, polypropylene, an ethylene- propylene copolymer, another polyolefin or polystyrene or a combination thereof) .
• a polymer such as for example polyethylene, polypropylene, an ethylene- propylene copolymer, another polyolefin or polystyrene or a combination thereof.
• Such polymeric supports may be formed by precipitating a polymer or by a prepolymerization, eg of monomers used in the polymerization for which the catalyst is intended.
• the support is especially preferably a metal or pseudo metal oxide such as silica, alumina or zirconia or a mixed oxide such as silica-alumina, in particular silica, alumina or silica-alumina.
• the support material is acidic, e.g. having an acidity greater than or equal to silica, more preferably greater than or equal to silica-alumina and even more preferably greater than or equal to alumina.
• the acidity of the support material can be studied and compared using the TPD (temperature programmed desorption of gas) method.
• the gas used will be ammonia. The more acidic the support, the higher will be its capacity to adsorb ammonia gas. After being saturated with ammonia, the sample of support material is heated in a controlled fashion and the quantity of ammonia desorbed is measured as a function of temperature .
• the support is a porous material so that the metallocene may be loaded into the pores of the support, e.g. using a process analogous to those described in W094/14856 (Mobil) , W095/12622 (Borealis) and WO96/00243 (Exxon) .
• the particle size is not critical but is preferably in the range 5 to 200 ⁇ m, more preferably 20 to 80 ⁇ m.
• the particulate support material is preferably calcined, ie heat treated, preferably under a non-reactive gas such as nitrogen. This treatment is preferably at a temperature in excess of 100°C, more preferably 200°C or higher, e.g. 200-800°C, particularly about 300°C.
• the calcination treatment is preferably effected for several hours, e.g. 2 to 30 hours, more preferably about 10 hours.
• the support may be treated with an alkylating agent before being loaded with the metallocene.
• Treatment with the alkylating agent may be effected using an alkylating agent in a gas or liquid phase, e.g. in an organic solvent for the alkylating agent.
• the alkylating agent may be any agent capable of introducing alkyl groups, preferably C x _ 6 alkyl groups and most especially preferably methyl groups. Such agents are well known in the field of synthetic organic chemistry.
• the alkylating agent is an organometallic compound, especially an organoaluminium compound (such as trimethylaluminium (TMA) , dimethyl aluminium chloride, triethylaluminium) or a compound such as methyl lithium, dimethyl magnesium, triethylboron, etc.
• TMA trimethylaluminium
• a compound such as methyl lithium, dimethyl magnesium, triethylboron, etc.
• TMA trimethylaluminium
• dimethyl aluminium chloride such as triethylaluminium
• a compound such as methyl lithium, dimethyl magnesium, triethylboron, etc.
• the quantity of alkylating agent used will depend upon the number of active sites on the surface of the carrier. Thus for example, for a silica support, surface hydroxyls are capable of reacting with the alkylating agent. In general, an excess of alkylating agent is preferably used with any unreacted alkylating agent subsequently being washed away
• an organoaluminium alkylating agent is used, this is preferably used in a quantity sufficient to provide a loading of at least 0.1 mmol Al/g carrier, especially at least 0.5 mmol Al/g, more especially at least 0.7 mmol Al/g, more preferably at least 1.4 mmol Al/g carrier, and still more preferably 2 to 3 mmol Al/g carrier.
• the surface area of the carrier is particularly high, lower aluminium loadings may be used.
• particularly preferred aluminium loadings with a surface area of 300-400 m 2 /g carrier may range from 0.5 to 3 mmol Al/g carrier while at surface areas of 700-800 m 2 /g carrier the particularly preferred range will be lower.
• the support is preferably removed from the treatment fluid and any excess treatment fluid is allowed to drain off.
• the optionally alkylated support material is loaded with the procatalyst, preferably using a solution of the procatalyst in an organic solvent therefor, e.g. as described in the patent publications referred to above.
• the volume of procatalyst solution used is from 50 to 500% of the pore volume of the carrier, more especially preferably 80 to 120%.
• the concentration of procatalyst compound in the solution used can vary from dilute to saturated depending on the amount of metallocene active sites that it is desired be loaded into the carrier pores .
• the active metal ie.
• the metal of the procatalyst is preferably loaded onto the support material at from 0.1 to 4%, preferably 0.5 to 3.0%, especially 1.0 to 2.0%, by weight metal relative to the dry weight of the support material .
• the loaded support may be recovered for use in olefin polymerization, e.g. by separation of any excess procatalyst solution and if desired drying of the loaded support, optionally at elevated temperatures, e.g. 25 to 80°C.
• a cocatalyst e.g. an alumoxane or an ionic catalyst activator (such as a boron or aluminium compound, especially a fluoroborate) may also be mixed with or loaded onto the catalyst support material . This may be done subsequently or more preferably simultaneously to loading of the procatalyst, for example by including the cocatalyst in the solution of the procatalyst or, by contacting the procatalyst loaded support material with a solution of the cocatalyst or catalyst activator, e.g. a solution in an organic solvent . Alternatively however any such further material may be added to the procatalyst loaded support material in the polymerization reactor or shortly before dosing of the catalyst material into the reactor.
• an alumoxane or an ionic catalyst activator such as a boron or aluminium compound, especially a fluoroborate
• a fluoroborate catalyst activator especially a B(C 6 F 5 ) 3 or more especially a ⁇ B(C 6 F 5 ) 4 compound, such as C 6 H 5 N(CH 3 ) 2 H:B (C 6 F 5 ) 4 or (C 5 H 5 ) 3 C:B (C 6 F 5 ) 4 .
• borates of general formula (cation) a (borate) b where a and b are positive numbers may also be used.
• cocatalyst or catalyst activator it is preferably used in a iuole ratio to the metallocene of from 0.1:1 to 10000:1, especially 1:1 to 50:1, particularly 1:2 to 30:1. More particularly, where an alumoxane cocatalyst is used, then for an unsupported catalyst the aluminium:metallocene metal (M) molar ratio is conveniently 2:1 to 10000:1, preferably 50:1 to 1000:1. Where the catalyst is supported the Al :M molar ratio is conveniently 2:1 to 10000:1 preferably 50:1 to 400:1.
• the B:M molar ratio is conveniently 2:1 to 1:2, preferably 9:10 to 10:9, especially 1:1.
• B:M molar ratio is typically 1:2 to 500:1, however some aluminium alkyl would normally also be used.
• ionic tetraaryl borate compounds it is preferred to use carbonium rather than ammonium counterions or to use B:M molar ratio 1:1.
• the olefin polymerized in the method of the invention is preferably ethylene or an alpha-olefin or a mixture of ethylene and an ⁇ -olefin or a mixture of alpha olefins, for example C 2 _ 20 olefins, e.g. ethylene, propene, n-but-1-ene, n-hex-1-ene, 4-methyl -pent-1-ene, n-oct-1-ene- etc.
• the olefins polymerized in the method of the invention may include any compound which includes unsaturated polymerizable groups.
• unsaturated compounds such as C 6 _ 20 olefins (including cyclic and polycyclic olefins (e.g. norbornene) ) , and polyenes, especially C 6 _ 20 dienes, may be included in a comonomer mixture with lower olefins, e.g. C 2 _ 5 ⁇ - olefins .
• Diolefins ie. dienes
• dienes are suitably used for introducing long chain branching into the resultant polymer. Examples of such dienes include ⁇ , ⁇ linear dienes such as 1, 5-hexadiene, 1, 6-r ⁇ eptadiene, 1,8- nonadiene, 1, 9-decadiene, etc.
• the polymer being produced is a homopolymer it will preferably be polyethylene or polypropylene. Where the polymer being produced is a copolymer it will likewise preferably be an ethylene or propylene copolymer with ethylene or propylene making up the major proportion (by number and more preferably by weight) of the monomer residues.
• Comonomers such as C 4 _ 6 alkenes, will generally be incorporated to contribute to the mechanical strength of the polymer product.
• metallocene catalysts yield relatively narrow molecular weight distribution polymers; however, if desired, the nature of the monomer/monomer mixture and the polymerization conditions may be changed during the polymerization process so as to produce a broad bimodal or multimodal molecular weight distribution (MWD) in the final polymer product.
• MWD molecular weight distribution
• the higher molecular weight component contributes to the strength of the end product while the lower molecular weight component contributes to the processability of the product, e.g. enabling the product to be used in extrusion and blow moulding processes, for example for the preparation of tubes, pipes, containers, etc.
• a multimodal MWD can be produced using a catalyst material with two or more different types of active polymerization sites, e.g. with one such site provided by the metallocene on the support and further sites being provided by further catalysts, e.g. Ziegler catalysts, other metallocenes, etc. included in the catalyst material .
• Polymerization in the method of the invention may be effected in one or more, e.g. 1, 2 or 3, polymerization reactors, using conventional polymerization techniques, e.g. gas phase, solution phase, slurry or bulk polymerization.
• a combination of slurry (or bulk) and at least one gas phase reactor is often preferred, particularly with the reactor order being slurry (or bulk) then one or more gas phase .
• the reaction temperature will generally be in the range 60 to 110°C (e.g. 85-110°C)
• the reactor pressure will generally be in the range 5 to 80 bar (e.g. 50-65 bar)
• the residence time will generally be in the range 0.3 to 5 hours (e.g. 0.5 to 2 hours) .
• the diluent used will generally be an aliphatic hydrocarbon having a boiling point in the range -70 to
• polymerization may if desired be effected under supercritical conditions.
• the reaction temperature used will generally be in the range 60 to 115°C (e.g. 70 to 110°C)
• the reactor pressure will generally be in the range 10 to 25 bar
• the residence time will generally be 1 to 8 hours.
• the gas used will commonly be a non-reactive gas such as nitrogen together with monomer (e.g. ethylene).
• the reaction temperature used will generally be in the range 130 to 270°C
• the reactor pressure will generally be in the range 20 to 400 bar
• the residence time will generally be in the range 0.005 to 1 hour.
• the solvent used will commonly be a hydrocarbon with a boiling point in the range 80-200°C.
• the quantity of catalyst used will depend upon the nature of the catalyst, the reactor types and conditions and the properties desired for the polymer product. Conventional catalyst quantities, such as described in the publications referred to herein, may be used.
• Figure 1 is a plot of catalyst activity for homopolymerisation of polyethylene using the procatalysts of Examples 3 to 5 and MAO or HIBAO.
• GC-MS analysis was performed using a Hewlett Packard 6890/5973 Mass Selective Detector in electron impact ionization mode (70eV) , equipped with a silica capillary column (30m x 0.25 mm i.d) .
• step 2 The cyclopentanones required for step 2 were prepared using a procedure (step 1) described in Bull. Soc. Chim. Fr. 2981-2991 (1970) .
• step 2 The siloxylation of step 2 followed the description in Organometallics 15_:5066-5086 (1996).
• Ligand activation and complexation were carried out using standard known procedures .
• Polymer was produced by ethylene homopoly erisation in a B ⁇ chi 2L stirred autoclave reactor 1200 ml of n- pentane was added to the reactor whereafter procatalyst and cocatalyst in solution in toluene were added to the reactor.
• MAO (30wt% in toluene)
• HIBAO 70 wt% in toluene
• the temperature was raised to 80°C and continuous ethylene feed was begun.
• the temperature was maintained at 80 °C and ethylene pressure was maintained at 10 bar for 30 minutes after which the reaction was terminated by stopping ethylene flow to the reactor and releasing the reactor overpressure.
• Polymer was prepared as in (i) above except that hydrogen (0.5 bar) was introduced from a 677 mL container together with the ethylene.
• Polymer was prepared as in (i) above except that isobutane was used as the polymerisation medium and the catalyst was added as a dried powder prepared by adding a toluene solution of procatalyst and cocatalyst to silica (Sylopol 55SJ from Grace, activated at 600°C) , stirring for 30 minutes and drying under nitrogen flow.
• silica Sylopol 55SJ from Grace, activated at 600°C
• Polymer was produced as in (i) above but with 30ml of hex-1-ene being added to the reactor before the ethylene.
• Polymer was produced as in (iv) above except that hydrogen (0.3 bar (v. a.) or 0.5 bar (v.b) ) was introduced from a 677 mL container together with the ethylene .
• Polymer was produced as (iii) above but with 30ml of hex-1-ene being added to the reactor before the ethylene .
• MAO (3ml 30wt% in toluene from Albemarle) and 0.5 ml of the MAO/metallocene solution prepared in (vii) above was mixed in a syringe and added to a 2L reactor equipped with a stirrer. Polymerisation was then effected as in (viii) above.
• Elemental analyses for carbon, hydrogen and nitrogen were carried out simultaneously with a CHNO- RAPID Analyzer from Elementar Analysensysteme GmbH working in principle as in Method C of ASTM 5291-92.
• the substance is combusted under an oxygen amosphere at 950°C.
• the combustion product gas stream after full oxidation of the component gases, is passed with helium as carrier gas over heated copper to remove excess oxygen and reduce nitrogen oxides to N 2 gas .
• the gases are then passed through a heatable chromatographic column to separate and elute N 2 , C0 2 , and H 2 0, in that order.
• the individual eluted gases are measured by a thermal conductivity detector.
• Chlorine determinations were performed by the oxygen flask method (e.g. DIN 53474). In this method the substance is wrapped in a piece of ash-free filter paper and burned in an oxygen filled flask, containing diluted sodium hydroxide solution as absorbent. Chlorine is then measured electrometrically by titration with standard AgN0 3 in the acidified solution. When handling air sensitive compounds, they are weighed under inert atmosphere in small gelatine capsules .
• Aluminum, chromium, and titanium were determined after destroying the organic matter by wet oxidation using sulfuric and nitric acid.
• Aluminum and chromium are measured by atomic absorption and titanium photometrically by means of the peroxodisulfatotitanic acid complex.
• Silicon analysis was done by atomic absorption from an alkaline solution after fusing the substance with sodium peroxide.
• Zirconium analysis was by ignition of the sample and weighing the oxide formed.
• Trimethylsiloxycyclopentadiene can also by synthesised according to the description in Acta. Chem.
• Method (A) 1- (Tertbutyldimethylsiloxy) -3 - methylcyclopentadiene was prepared analogously to Example 4 (using commercially available 3- methylcyclopent-2-en-l-one (Fluka 66545)) as starting material. Yield 43%. The product was characterised by GC/MS (several isomers showing M + at m/z 210) .
• the organic phase is agitated with 100 ml 5% NaHC0 3 solution and 100 ml NH 4 C1 solution and is then dried over MgS0 4 . After filtering and centrifuging off of the solvents (40° C bath temperature, 100 mbar) a clear fluid is obtained as a raw product which is purified by vacuum distillation (Boiling point: 58 - 61° C at 1.5 - 2 mbar). Yield: 3.82 g (34 . 9% ) .
• the product was characterised by GC/MS technique, which showed the presence of three components (GC) each showing M + peak at 224 (MS) .
• Pentane removal resulted in a light yellow crude product, which was recrystallised in pentane to afford 800 mg of yellow crystalline bis(t- butyldimethylsiloxy-3 , 4-dimethylcyclopentadienyl) zirconium dichloride. Yield 44%.
• the product was also characterised by mass spectroscopy (M + at m/z 637) .
• Triisopropylsiloxycyclopentadiene was prepared analogously to Example 4 using triisopropylsilyltrifluoromethylsulfonate (Fluka 91746) and cyclopent-2-enone (Fluka 29827) as starting materials. It was not isolated and analysed but lithiated immediately to avoid spontaneous Diels-Alder dimerisation. Lithiation was performed analogously to
• Dimethylsilanediylbis (1,1'- (3- triisopropylsiloxycyclopentadienyl) dilithium was prepared analogously to Example 4 using 2 equivalents of base. Yield 40%.
• rac-Dimethylsilanediylbis (1,1'- (3- triisopropylsiloxycyclopentadienyl) zirconium dichloride was prepared analogously to Example 4 using 1 equivalent of the dilithium salt.
• the pentane insolubles were extracted using toluene to afford the title compound (rac.-meso>20 :1) in 18% yield.
• meso-Dimethylsilanediylbis (1, 1 ' - (3- triisopropylsiloxycyclopentadienyl) zirconium dichloride was isolated by recrystallisation of the pentane solubles of the crude product of Example 7 in pentane. Yield of the title compound 18%, rac :meso «l : 5.
• the product was characterised by GC/MS (main peak in GC curve had M + at m/z 504) .
• Method (A) 20.0 g (120.3 mmol) of fluorene (Fluka 46880) and 150 ml of toluene were mixed at room temperature. 90.0 ml (135 mmol) of 1.50 M solution of t-BuLi in hexanes was added over 10 minutes with stirring. After 15 hours the mixture was filtered and toluene insolubles washed with 2 x 100 ml of toluene. 12.7 g of fluorenyl lithium was isolated upon drying under reduced pressure. Yield 61%.
• Method (A) 26 g (ca. 200 mmol) of dichlorodimethylsilane was mixed with 10 ml of THF. 5.0 g (29 mmol) of fluorenyl lithium was dissolved in 30 ml of THF and the solution was added to silane/THF at 60 °C over 30 seconds with stirring. After 50 minutes at 60 °C the solvent was removed under reduced pressure and the residue was extracted with 50 ml of pentane. 1.9 g of chlorodimethylfluorenylsilane slightly contaminated by dimethylbisfluorenylsilane was isolated upon solvent removal. Sublimation (100°C, 0.03 mbar) resulted in chlorodimethylfluoren-9-ylsilane. Calculated yield after sublimation 17%.
• Dimethylsilanediyl (3-triisopropylsiloxycyclopentadien-l- yl) (fluoren-9-yl) zirconium dichloride was prepared analogously to Example 9. It was isolated by double crystallisation (toluene, dichloromethane) in 9% yield.
• Method (B) At 20°C, 23.9 ml (38.2 mmol) of t-BuLi in hexanes was added to 8.8 g (19.1 mmol) of (3 -triisopropylsiloxy- cyclopentadien-1-yl) (9-fluorenyl) dimethylsilane dissolved in 100 ml of pentane. After 18 hours, filtration, washing with pentane and solvent removal resulted in 8.7 g (18.4 mmol) of dimethylsilanediyl (9- fluorenyl) (3-triisopropylsiloxycyclopentadien-l- yl) dilithium. Yield 95%.
• Polyethylene was prepared using the procatalysts of Examples 3, 4, 5, 6, 7, 9 and 10.
• the quantities of procatalyst used, the co-catalyst used, the polymerisation techniques used, the catalyst activities, the polymer yields, and polymer properties are set out in Table 1 below.
• LLDPE was produced using the procatalysts of Examples 3 to 9 and 1-hexene as comonomer.
• the quantities of procatalyst used, the co-catalyst used, the polymerisation techniques used, the catalyst activities, the polymer yields, and polymer properties are set out in Table 2 below
• the complex rac-Me 2 Si (3-iPr 3 SiO-Cp) 2 ZrCl 2 , 9 mg, was dissolved in 1.8g of MAO solution (30 w% in toluene from Albermarle), and stirred for 30 minutes (Al :Zr 8200) .
• the 0.25g portion of the complex solution above (0.15 ml) and additional 3.0 ml MAO solution (30 w% in toluene) was charged to a 2 litre steel reactor, 650 ml liq propylene added. Prepolymerisation at 15°C for 8 minutes, and then rapid heat-up to 70°C, and continued for 60 minutes. Polymerisation was ended by depressurizing the reactor, and powder was vacuum dried.
• Heterogenised catalyst was added as dry powder to an inert 2 litre reactor. Propylene (650 ml at 15°C) was added, and stirrer activated. Prepolymerisation at 15°C for 8 minutes, and then rapid heat-up to 70°C, and continuedfor 60 minutes. Polymerisation was ended by depressurizing the reactor, and powder was vacuum dried. In subsequent runs, triethyl aluminium and hydrogen was added, see results table.
• procatalyst typically 4 mg is weighed to a septum flask in a glove box and a toluene solution of MAO (Albemarle, 15.5%-w of Al) is added to reach an Al : Zr molar ratio of 1000. The appropriate amount of the catalyst solution is injected into an addition vessel
• the reactor is evacuated and flushed with nitrogen several times at 70°C. At 15-17°C, 200 ⁇ l of 10%-wt. solution of triethylaluminum in pentane and 1.1 kg of liquid propene are added and stirring started. The catalyst is fed to the reactor and heating is started. After the appropriate period of time at run temperature the reactor is vented, flushed with nitrogen, opened and the polymer is isolated.
• a heterogenized catalyst is prepared by adding procatalyst and MAO to a calcined silica carrier (Sylopol 55SJ) to give a 0.2% wt . Zr content and an Al:Zr molar ratio of 200.
• the reactor is evacuated and flushed with nitrogen several times at 70°C. At 15-17°C, 200 ⁇ l of 10%-wt. solution of triethylaluminum in pentane and 1.1 kg of liquid propene are added and stirring started. The catalyst is fed to the reactor and heating is started. After the appropriate period of time at run temperature the reactor is vented, flushed with nitrogen, opened and the polymer is isolated.
• Three metallocenes of similar structure to the compounds of the invention were similarly tested for catalyst activity using MAO and HIBAO cocatalysts.
• the compounds tested were rac-ethylene-bis (2- tertbutyldimethylsiloxyindenyl) zirconium dichloride (Compound A) , rac-ethylene-bisindenyl zirconium dichloride (Compound B) and bis (n-butylcyclopentadienyl) zirconium dichloride (Compound C) .
• the results, set out in Table 4 below demonstrate poor or relatively poor activity with HIBAO.

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