EP2640757A2 - Procédés de production de polyoléfines ayant une distribution des poids moléculaires multimodale - Google Patents

Procédés de production de polyoléfines ayant une distribution des poids moléculaires multimodale

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Publication number
EP2640757A2
EP2640757A2 EP11841727.8A EP11841727A EP2640757A2 EP 2640757 A2 EP2640757 A2 EP 2640757A2 EP 11841727 A EP11841727 A EP 11841727A EP 2640757 A2 EP2640757 A2 EP 2640757A2
Authority
EP
European Patent Office
Prior art keywords
group
polymerization catalyst
transition metal
catalyst
polymerization
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP11841727.8A
Other languages
German (de)
English (en)
Other versions
EP2640757A4 (fr
Inventor
Matthew W. Holtcamp
Matthew S. Bedoya
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ExxonMobil Chemical Patents Inc
Original Assignee
ExxonMobil Chemical Patents Inc
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Publication date
Priority claimed from US12/950,501 external-priority patent/US8148470B1/en
Application filed by ExxonMobil Chemical Patents Inc filed Critical ExxonMobil Chemical Patents Inc
Priority to EP11841727.8A priority Critical patent/EP2640757A4/fr
Publication of EP2640757A2 publication Critical patent/EP2640757A2/fr
Publication of EP2640757A4 publication Critical patent/EP2640757A4/fr
Withdrawn legal-status Critical Current

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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
    • 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
    • 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
    • C08F4/639—Component covered by group C08F4/62 containing a transition metal-carbon bond
    • C08F4/6392—Component covered by group C08F4/62 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
    • C08F4/63922—Component covered by group C08F4/62 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not
    • C08F4/63925—Component covered by group C08F4/62 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not two cyclopentadienyl rings being mutually non-bridged
    • 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
    • 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
    • C08F4/6592—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
    • C08F4/65922—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not
    • C08F4/65925—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not two cyclopentadienyl rings being mutually non-bridged

Definitions

  • TITLE PROCESSES FOR MAKING MULTIMODAL MOLECULAR WEIGHT DISTRIBUTION POLYOLEFINS
  • This invention relates to the field of olefin polymerization, particularly methods for the polymerization and copolymerization of olefins using a mixed catalyst composition.
  • Polyolefms having a bimodal molecular weight distribution are desirable because they can combine the advantageous mechanical properties of the high molecular weight fraction with the improved processing properties of the low molecular weight fraction.
  • This provides a polyolefm with a useful and desirable combination of properties, as compared to polyolefms of the high molecular weight fraction or the low molecular weight fraction alone.
  • typically high molecular weight confers desirable mechanical properties and stable bubble formation onto polyolefm polymers, it also often inhibits extrusion processing by increasing backpressure in extruders, promotes melt fracture defects in the inflating bubble, and potentially, promotes too high a degree of orientation in the finished film.
  • low molecular weight polyolefms typically have excellent processibility, but poor strength.
  • a multimodal molecular weight distribution polyolefm comprising both a low molecular weight fraction and a high molecular weight fraction retaining the desirable mechanical properties, stable bubble formation, reduced extruder backpressure, and inhibited melt fracture is thus desirable.
  • Such polyolefms could find tremendous utility in films and other articles requiring such a useful and desirable combination of properties.
  • Polyolefms having a multimodal molecular weight distribution may be obtained by physically blending a high molecular weight polyolefm with a low molecular weight polyolefm, as disclosed in U.S. Patent No. 4,461,873.
  • these physically produced blends typically contain high gel levels, which lead to poor film appearance due to those gels.
  • blending tends to be expensive, requires complete homogeneity of the melt blend, and adds a cumbersome additional blending step to the manufacturing/fabrication process.
  • Some industrial processes operate using multiple reactor technology to produce a processable bimodal molecular weight distribution polyethylene product in two or more reactors.
  • each reactor produces a single component of the final product.
  • the production of bimodal molecular weight distribution high density polyethylene is carried out by a two step process, using two reactors in series.
  • the process conditions and the catalyst can be optimized in order to provide a high efficiency and yield for each step in the overall process.
  • using multiple reactor technology adds cost and processing considerations.
  • bimodal molecular weight distribution polyolefms such as bimodal molecular weight distribution polyethylene
  • a single catalyst because two separate sets of reaction conditions are typically needed.
  • others in the art have tried to produce two polymers together at the same time, in the same reactor, using two different catalysts.
  • Catalyst systems comprising two different metallocene catalysts are disclosed in the production of bimodal molecular weight distribution polyolefms in EP 0 619 325.
  • EP 0 619 325 describes a process for preparing polyolefms, such as polyethylenes, having a multimodal or at least bimodal molecular weight distribution.
  • the metallocenes used are, for example, a bis(cyclopentadienyl) zirconium dichloride and an ethylene-bis(indenyl) zirconium dichloride.
  • WO 99/03899 discloses the use of a catalyst composition which produces, in a single reactor, polyethylene with a broad or bimodal molecular weight distribution.
  • the catalyst is prepared from the interaction of silica, previously calcined at 600°C, with dibutylmagnesium, 1-butanol and titanium tetrachloride, and a solution of methylalumoxane and ethylenebis[l-indenyl] zirconium dichloride.
  • U.S. Patent No. 7,163,906 discloses a catalyst composition comprising the contact product of at least one metallocene compound, at least one organochromium polymerization catalyst, a fluorided silica, and at least one alkyl aluminum compound, which is then used to polymerize ethylene in an inert atmosphere.
  • the metallocene used in the Examples of U.S. Patent No. 7,163,906 is bis(n-butylcyclopentadienyl)zirconium dichloride and the organochromium compounds used include dicumene chromium and chromocene.
  • U.S. Patent No. 7,163,906 produced polyethylenes characterized by very broad molecular weight distributions, ranging from 70.3 to 8.4.
  • the polyethylene produced in U.S. Patent No. 7,163,906 exhibits an intermediate molecular weight distribution with a central high peak attributed to metallocene component and broad tails on both high and low molecular weight sides attributed to the chromium component. Further, U.S. Patent No. 7,163,906 does not disclose using a molecular switch to activate one catalyst and deactivate the other.
  • This invention relates to a process to make a multimodal polyolefm composition
  • a process to make a multimodal polyolefm composition comprising: (i) contacting at least one first olefin monomer with a mixed catalyst system, under polymerization conditions, to produce at least a first polyolefm component having a Mw of 5,000 g/mol to 600,000 g/mol
  • the mixed catalyst system comprises: (a) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (b) at least one organochromium polymerization catalyst; (c) an activator; and (d) a support material; (ii) thereafter, contacting the first polyolefm component/mixed catalyst system combination with a molecular switch; (iii) contacting the first polyolefm component/mixed catalyst system combination with at least one second olefin monomer, which may be the same or different from the first olefin monomer, under polymerization conditions; and
  • This invention further relates to a mixed catalyst system comprising: (i) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (ii) an activator; (iii) at least one organochromium polymerization catalyst; and (iv) a support material; wherein under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active, the organochromium polymerization catalyst has an activity at least 50% less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal; and wherein after contact with a molecular switch and under polymerization conditions, the organochromium polymerization catalyst has an activity at least 50% greater than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal.
  • This invention further relates to a method of making a supported mixed catalyst system comprising: (i) contacting a support material with a polymerization catalyst comprising a Group 4 or a Group 5 transition metal and an activator, such that the reactive groups on the support material are titrated, to form a supported polymerization catalyst; and (ii) thereafter contacting the supported polymerization catalyst with an organochromium polymerization catalyst to form a supported mixed catalyst system; wherein under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active, the organochromium polymerization catalyst has an activity at least 50% less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal; and wherein after contact with a molecular switch and under polymerization conditions, the organochromium polymerization catalyst has an activity at least 50% greater than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal.
  • Figure 1 represents a monomodal polyethylene molecular weight distribution obtained using Catalyst 2 (a supported bis(l -methyl, 3 -butyl cyclopentadienyl)zirconium dichloride/bis(cyclopentadienyl) chromium mixed catalyst system).
  • Figure 2 represents a bimodal polyethylene molecular weight distribution obtained using Catalyst 2 activated by a molecular switch (a supported bis(l -methyl, 3 -butyl cyclopentadienyl)zirconium dichloride/ bis(cyclopentadienyl) chromium mixed catalyst system, exposed to oxygen and triethylaluminum).
  • a molecular switch a supported bis(l -methyl, 3 -butyl cyclopentadienyl)zirconium dichloride/ bis(cyclopentadienyl) chromium mixed catalyst system, exposed to oxygen and triethylaluminum.
  • molecular weight means weight average molecular weight (Mw), unless otherwise stated.
  • the invention relates to a process comprising: (i) contacting at least one first olefin monomer with a mixed catalyst system, under polymerization conditions, to produce at least a first polyolefin component having a Mw of 5,000 g/mol to 600,000 g/mol, wherein the mixed catalyst system comprises: (a) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (b) at least one organochromium polymerization catalyst; (c) an activator; and (d) a support material; (ii) thereafter, contacting the first polyolefin component/mixed catalyst system combination with a molecular switch; (iii) contacting the first polyolefin component/mixed catalyst system combination with at least one second olefin monomer, which may be the same or different, under polymerization conditions; and (iv) obtaining a multimodal polyolefin composition.
  • the mixed catalyst system comprises: (a) at least one polymerization catalyst comprising
  • an "olefin,” alternatively referred to as “alkene,” is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond.
  • olefin is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond.
  • the olefin present in the polymer is the polymerized form of the olefin.
  • a “polymer” has two or more of the same or different mer units.
  • a “copolymer” is a polymer having two or more mer units that are different from each other.
  • a “terpolymer” is a polymer having three mer units that are different from each other. "Different" as used to refer to mer units indicates that the mer units differ from each other by at least one atom or are different isomerically.
  • the term "mixed catalyst system” is used to mean any composition or mixture that includes (i) at least two different catalyst compounds, herein, a polymerization catalyst comprising a Group 4 or Group 5 transition metal which is capable of being quenched or deactivated by a molecular switch and an organochromium polymerization catalyst which is capable of being activated by a molecular switch; (ii) an activator; and (iii) a support material, the components as described below.
  • multimodal when used to describe a polymer or polymer composition means “multimodal molecular weight distribution,” which is understood to mean that the Gel Permeation Chromatography (GPC) trace, plotted as d(wt%)/d(Log[M]) versus weight average molecular weight (g/mole), has more than one peak or inflection points.
  • An "inflection point” is that point where the second derivative of the curve changes in sign (e.g., from negative to positive or vice versa).
  • a polyolefin composition that includes a first low molecular weight polymer component and a second high molecular weight polymer component is considered to be a "bimodal" polyolefin composition.
  • the polymer composition has a "molecular weight distribution” (or MWD) which means the ratio of Mw to number average molecular weight (Mn) or Mw/Mn. Mw and Mn are determined by GPC.
  • a "molecular switch,” as used herein, serves to decrease, or switch off, or quench the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal, and increase or switch on the activity of the organochromium polymerization catalyst.
  • the molecular switch comprises a first component of oxygen and a second component of an alkyl aluminum compound. The components of the molecular switch may be introduced to the process sequentially.
  • the oxygen is contacted with the first polyolefm component/mixed catalyst system, and thereafter the alkyl aluminum compound is added under polymerization conditions, including, preferentially, an inert atmosphere.
  • Catalyst activity is a measure of how many grams of polymer (P) are produced using a polymerization catalyst comprising W of transition metal (M), over a period of time of T hours; and may be expressed by the following formula: P/(T x W).
  • Active as used herein to refer to polymerization catalysts, means the polymerization catalyst has a catalyst activity of at least 50 g(molM) ⁇ lhr ⁇ l, where M is the transition metal moiety present in the catalyst component of the mixed catalyst system that the activity can be attributed to.
  • “Inactive,” as used herein to refer to polymerization catalysts means the polymerization catalyst has a catalyst activity of less than 50 g ⁇ olM ⁇ hr 1 .
  • activity is calculated, as shown above, from polymerization data obtained from a polymerization conducted in a 75 mL cylindrical reactor, at a pressure of 200 psi (1.38 MPa), and with ethylene. The reactor was then heated to a temperature of 85°C and kept at this temperature for 45 minutes.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal and the organochromium polymerization catalyst differ in molecular switch response.
  • Molecular switch response refers to the relative activity of the catalysts after contact with the molecular switch, for example, exposure to oxygen for 5 minutes, and then subject to activation with an alkyl aluminum compound under polymerization conditions, as compared with the activity of the same catalysts under polymerization conditions including an inert atmosphere.
  • a catalyst may become deactivated and lose catalyst activity (negative molecular switch response); maintain catalyst activity (no molecular switch response); or become activated and/or increase in catalyst activity (positive molecular switch response).
  • Molecular switch response may be determined by ratio of the difference between catalyst component activity (A 0 ) after exposure to oxygen, then to subsequent polymerization conditions, including activation with an alkyl aluminum compound, and the catalyst component activity (A j ) of the mixed catalyst system that has not been exposed to oxygen, under polymerization conditions, including preferably an inert atmosphere; and is represented by the formula: (A 0 - Aj)/ Aj.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal typically produces polymer, giving a unimodal or bimodal molecular weight distribution, as the first polyolefin component.
  • the organochromium polymerization catalyst does not appear to produce much polymer.
  • the organochromium polymerization catalyst under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active, has an activity at least 50% less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal, at least 60% less, at least 70%> less, at least 80%> less, at least 90%> less, or at least 98%> less.
  • the organochromium polymerization catalyst has an activity at least one order less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal, at least two orders less, at least 3 orders less, at least 5 orders less, or at least 6 orders less.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal has an activity at least 50% greater than the activity of the organochromium polymerization catalyst, at least 60% greater, at least 70% greater, at least 80% greater, at least 90% greater, or at least 98% greater.
  • the organochromium polymerization catalyst has an activity at least one order more than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal, at least two orders more, at least 3 orders more, at least 5 orders more, or at least 6 orders more.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal typically ceases to produce appreciable amounts of polymer.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is deactivated or quenched by contact with the molecular switch, and does not produce appreciable quantities of additional first polyolefin component. This is observed as a lack of growth of the mode of the first polyolefin component in the GPC trace. Accordingly, for polymerization catalysts comprising a Group 4 or Group 5 transition metal, the A 0 is less than the A j .
  • the polymerization catalyst comprising a Group 4 or a Group 5 transition metal has a negative molecular switch response.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal after contact with a molecular switch and under polymerization conditions, is less active than the organochromium polymerization catalyst.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is at least 50% less active than the organochromium polymerization catalyst, at least 60% less, at least 70%> less, at least 80%> less, at least 90%> less, or at least 98%> less, after contact with the molecular switch.
  • the catalyst comprising a Group 4 or Group 5 transition metal has an activity at least one order less than the activity of the organochromium polymerization catalyst polymerization, at least two orders less, at least 3 orders less, at least 5 orders less, or at least 6 orders less.
  • the organochromium polymerization catalyst typically produces increased amounts of polymer. This is observed due to a growth of a mode of an additional polymer component, different in molecular weight than the first polyolefm component, in the GPC trace. Accordingly, for organochromium polymerization catalysts, the A Q is greater than the A j . Accordingly, the organochromium polymerization catalyst has a positive molecular switch response.
  • the organochromium polymerization catalyst after contact with a molecular switch, preferably comprising oxygen and an alkyl aluminum compound, and under polymerization conditions, is more active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal. In some embodiments, the organochromium polymerization catalyst is at least 50% more active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal, at least 60% more, at least 70% more, at least 80% more, at least 90% more, or at least 98% more, after contact with the molecular switch.
  • the organochromium polymerization catalyst has an activity at least one order more than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal, at least two orders more, at least 3 orders more, at least 5 orders more, or at least 6 orders more.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal after contact with a molecular switch, under polymerization conditions, the polymerization catalyst comprising a Group 4 or Group 5 transition metal has a negative molecular switch response and the organochromium polymerization catalyst has a positive molecular switch response.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is inactive in step (iii) of the polymerization process, and the organochromium compound is inactive in step (i) of the polymerization process.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active in step (i) of the polymerization process, and the organochromium compound is active in step (iii) of the polymerization process.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active in step (i) of the polymerization process and inactive in step (iii).
  • the organochromium compound is inactive in step (i) of the polymerization process and active in step (iii).
  • the mixed catalyst system of the present invention comprises: (i) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (ii) an activator; (iii) at least one organochromium polymerization catalyst; and (iv) a support material; wherein under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active, the organochromium polymerization catalyst has an activity at least 50% less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal; and wherein after contact with a molecular switch, and under polymerization conditions, the organochromium polymerization catalyst is at least 50% more active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal.
  • This invention further relates to a method of making a mixed catalyst system comprising: (i) contacting a support material with a polymerization catalyst comprising a Group 4 or a Group 5 transition metal and an activator, such that the reactive groups on the support material are titrated, to form a supported polymerization catalyst; (ii) thereafter contacting the supported polymerization catalyst with an organochromium polymerization catalyst to form a supported mixed catalyst system; wherein the organochromium polymerization catalyst and the polymerization catalyst comprising a Group 4 or Group 5 transition metal differ in molecular switch response by at least 50%; and wherein the organochromium polymerization catalyst of the supported mixed catalyst system is less active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal by at least 50%, under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active.
  • the invention relates to a process comprising: (i) contacting at least one first olefin monomer with a mixed catalyst system, under polymerization conditions; to produce at least a first polyolefin component having a Mw of 5,000 g/mole to 600,000 g/mole; preferably 8,000 g/mole to 400,000 g/mole; or 10,000 g/mole to 300,000 g/mole; wherein the mixed catalyst system comprises: (a) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (b) at least one organochromium polymerization catalyst; (c) an activator; and (d) a support material; (ii) thereafter, contacting the first polyolefin component/mixed catalyst system combination with a molecular switch, preferably comprising oxygen and an alkyl aluminum compound; (iii) contacting the first polyolefin component/mixed catalyst system combination with at least one second o
  • Processes of this invention can be carried out in any manner known in the art.
  • Any suspension, homogeneous bulk, solution, slurry, or gas phase polymerization process known in the art can be used. Gas phase and slurry polymerization processes are preferred.
  • the processes of the invention may be batch, semi-batch, or continuous.
  • continuous means a system that operates without interruption or cessation.
  • a continuous process to produce a polymer composition would be one where the reactants are continually introduced into one or more reactors and polymer composition products are continually withdrawn.
  • a continuous cycle is typically employed where in one part of the cycle of a reactor system, a cycling gas stream, otherwise known as a recycle stream or fluidizing medium, is heated in the reactor by the heat of polymerization.
  • a cycling gas stream otherwise known as a recycle stream or fluidizing medium
  • This heat is removed from the recycle composition in another part of the cycle by a cooling system external to the reactor.
  • a gas fluidized bed process for producing polymers a gaseous stream containing one or more monomers is continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions. The gaseous stream is withdrawn from the fluidized bed and recycled back into the reactor. Simultaneously, polymer product is withdrawn from the reactor and fresh monomer is added to replace the polymerized monomer.
  • a suspension of solid, particulate polymer is formed in a liquid polymerization diluent medium to which ethylene and comonomers and often hydrogen along with catalyst are added.
  • the suspension including diluent is intermittently or continuously removed from the reactor where the volatile components are separated from the polymer and recycled, optionally after a distillation, to the reactor.
  • the liquid diluent employed in the polymerization medium is typically an alkane having from 3 to 7 carbon atoms, preferably a branched alkane.
  • the medium employed should be liquid under the conditions of polymerization and relatively inert. When a propane medium is used, the process must be operated above the reaction diluent critical temperature and pressure.
  • a hexane or an isobutane medium is employed.
  • a particle form polymerization i.e., a type of slurry process
  • a type of slurry process can be used wherein the temperature is kept below the temperature at which the polymer goes into solution.
  • Such technique is well known in the art, and described in for instance U.S. Patent No. 3,248,179.
  • Other slurry processes include those employing a loop reactor and those utilizing a plurality of stirred reactors in series, parallel, or combinations thereof.
  • Non-limiting examples of slurry processes include continuous loop or stirred tank processes.
  • other examples of slurry processes are described in U.S. Patent No. 4,613,484.
  • the processes of this invention may be conducted in any of glass lined, stainless steel, or similar type reaction equipment.
  • Useful reaction vessels include reactors (including continuous stirred tank reactors, batch reactors, reactive extruder, pipe or pump, continuous flow fixed bed reactors, slurry reactors, fluidized bed reactors, and catalytic distillation reactors).
  • the reaction zone may be fitted with one or more internal and/or external heat exchanger(s) in order to control undue temperature fluctuations.
  • the weight hourly space velocity given in units of g m g c _1 h _1 , that is, grams monomer feed (g m ) per gram catalyst (g c ) per hour (h), will determine the relative quantities of monomer feed to catalyst employed, as well as the residence time in the reactor of the monomer.
  • the weight hourly space velocity of the monomer is typically greater than 0.04 BmBc "1 ! 1"1 and preferably, greater than 0.1 gmgc ⁇ h "1 .
  • Typical polymerization conditions include temperature, pressure, and residence time.
  • at least one first olefin monomer is contacted with a mixed catalyst system, under polymerization conditions; to produce at least a first polyolefm component having a Mw of 5,000 g/mole to 600,000 g/mole.
  • the temperature of the polymerization process may be in the range of from about 0°C to about 300°C, preferably from about 60°C to about 280°C, or more preferably from about 70°C to about 150°C. If the process is conducted in a batch reactor, then the residence time of the olefin monomer and catalyst can be of any duration, provided that the desired polymer products are obtained.
  • the residence time in a reactor is in the range of from about 15 minutes to about 240 minutes, preferably from about 30 minutes to about 210 minutes, or preferably from about 45 minutes to about 180 minutes.
  • the polymerization reaction pressure can be any pressure that does not adversely affect the polymerization reaction, and may be in the range of from about 0.1 to about 1000 psi (0.7 kPa to 6.9 MPa), preferably from about 20 to about 400 psi (0.14 MPa to 2.8MPa), or preferably from about 50 to about 250 psi (0.34 MPa to 1.7MPa).
  • the reactants for example, monomer, supported mixed catalyst; optional diluent, etc.
  • a temperature in the range of from about 0°C to about 300°C, preferably from about 60°C to about 280°C, or more preferably from about 70°C to about 150°C; a pressure in the range of from about 0.1 to about 1000 psi (0.7 kPa to 6.9 MPa), preferably from about 20 to about 400 psi (0.14 MPa to 2.8MPa), or preferably from about 50 to about 250 psi (0.34 MPa to 1.7MPa); and a residence time in the range of from about 15 minutes to about 240 minutes, preferably from about 30 minutes to about 210 minutes, or preferably from about 45 minutes to about 180 minutes.
  • the olefin pressure is greater than 5 psig (34.5 kPa); preferably, greater than 10 psig (68.9 kPa); and more preferably, greater than 45 psig (310 kPa).
  • the aforementioned pressure ranges may also be suitably employed as the total pressure of olefin and diluent.
  • the aforementioned pressure ranges may be suitably employed for the inert gas pressure.
  • Suitable diluents/solvents for the process include non-coordinating, inert liquids.
  • Examples include straight and branched-chain hydrocarbons such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof, including those that can be found commercially (IsoparTM); perhalogenated hydrocarbons such as perfluorinated C 4 .
  • the feed concentration of the monomers for the polymerization is 60 volume % solvent or less, preferably 40 volume % or less, preferably 20 volume % or less, based on the total volume of the feedstream.
  • Suitable additives to the polymerization process can include one or more scavengers, activators, promoters, chain transfer agents, chain shuttle agents (such as diethyl zinc), modifiers, reducing agents, oxidizing agents, hydrogen, or silanes.
  • Monomers useful herein include olefins, in particular, ethylene, propylene, butene, pentene, hexane, heptane, octene, nonene, decene, undecene, and dodecane, and isomers thereof.
  • a single olefin is contacted with the mixed catalyst system, preferably ethylene or propylene.
  • more than one olefin, preferably two olefins, or preferably three olefins, are contacted with the mixed catalyst system.
  • the copolymer may be a ethylene/propylene, ethylene/butene, ethylene/pentene, ethylene/hexane, or ethylene/octene copolymer.
  • the comonomer content is less than 50 weight %, based on the total weight of the polymer; less than 40 weight %; less than 30 weight %; less than 20 weight %; less than 10 weight %; or less than 5 weight %.
  • the quantity of supported mixed catalyst that is employed in the process of this invention is any quantity that provides for an operable polymerization reaction.
  • the ratio of moles of monomer feed to moles of supported mixed catalyst, based on moles of transition metal is typically greater than 10:1 , preferably greater than 100: 1, preferably greater than 1,000: 1, preferably greater than 10,000: 1, preferably greater than 25,000: 1, preferably greater than 50,000: 1, preferably greater than 100,000: 1.
  • the molar ratio of monomer feed to supported mixed catalyst is typically less than 10,000,000: 1, preferably less than 1,000,000: 1, and more preferably less than 500,000: 1.
  • the molecular weight of the polymers may be controlled in a known manner, e.g., by using hydrogen. Molecular weight control is evidenced by an increase in the melt index of the polymer when the molar ratio of hydrogen to monomer olefin in the reactor is increased.
  • a "reactor” is any container(s) in which a chemical reaction occurs.
  • the processes of the present invention that is steps (i) to (iv), are carried out in the same reactor.
  • steps (i) to (iv) are carried out in different reaction zones in the same reactor.
  • steps (i) to (iv) are carried out in a tubular reactor.
  • steps (i) to (iv) are carried out in a gas phase reactor.
  • the processes of the present invention are carried out in two or more reactors.
  • Production of polymers in multiple reactors can include several stages in at least two separate polymerization reactors interconnected by a transfer device making it possible to transfer the polymers resulting from the first polymerization reactor into the second reactor.
  • polymerization in multiple reactors can include the manual transfer of polymer from one reactor to subsequent reactors for continued polymerization.
  • the polymerization conditions in one of the reactors can be different from the polymerization conditions of the other reactors.
  • Such reactors can include any combination, including multiple loop reactors, multiple gas reactors, a combination of loop and gas reactors, a combination of autoclave reactors or solution reactors with gas or loop reactors, multiple solution reactors, or multiple autoclave reactors.
  • the oxygen may be introduced into the first reactor before transfer of the first polymer/mixed catalyst composition to the second reactor, during transfer, or into the second reactor.
  • the reactants for example, supported mixed catalyst; optional diluent, etc.
  • the first polyolefm component/mixed catalyst system combination is contacted with oxygen.
  • Oxygen may be introduced into the process by any manner known in the art.
  • the reaction is terminated by the removal of the olefin and then the first polyolefm component/mixed catalyst system combination is contacted with a molecular switch.
  • the molecular switch of the present invention has a first component of oxygen, and a second component of an alkyl aluminum compound.
  • a "molecular switch,” as used herein, decreases, or switches off, or quenches the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal, and increases or switches on the activity of the organochromium polymerization catalyst.
  • the molecular switch comprises a first component of oxygen and a second component of an alkyl aluminum compound.
  • the components of the molecular switch are preferably added to the process sequentially.
  • the oxygen is contacted with the first polyolefm component/mixed catalyst system, and thereafter the alkyl aluminum compound is added under polymerization conditions, including, preferably, an inert atmosphere.
  • the oxygen is the first component of the molecular switch of the present invention.
  • oxygen employed may be in the form of molecular oxygen or an oxygen containing medium (gas, liquid, solid), for example an oxygen containing gas, such as air.
  • the molecular switch comprises oxygen in the form of air.
  • the first polyolefm component/mixed catalyst system combination is contacted with oxygen in an amount sufficient to deactivate the polymerization catalyst comprising a Group 4 or Group 5 transition metal and oxygenate the organochromium polymerization catalyst.
  • Oxygenate as used herein, means to react with the organochromium polymerization catalyst to produce a precatalyst.
  • a "precatalyst” as used herein, refers to a catalyst compound which is activated by the second component of the molecular switch, the alkyl aluminum compound.
  • the oxygenated organochromium precatalyst is activated by the second component of the molecular switch, the alkyl aluminum compound.
  • the alkyl aluminum compounds are represented by the general formulae: AIR3 or AlR jH in which each R is, independently, a hydrocarbyl radical (preferably alkyl, comprising from 2 to 10 carbon atoms) or a halide. Compounds of the formula AIR3 are preferred.
  • alkyl aluminum compounds examples include trimethylaluminum, triethylaluminum, triisobutylaluminum, tri-n-hexylaluminum, tri-n- octylaluminum, tri-iso-octylaluminum, triphenylaluminum, tripropylaluminum, diethylaluminum ethoxide, tributylaluminum, diisobutylaluminum hydride, and diethylaluminum chloride, and the like.
  • the mixed catalyst system of the present invention comprises: (a) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (b) at least one organochromium polymerization catalyst; (c) an activator; and (d) a support material, as discussed below.
  • the first polyolefm component/mixed catalyst system combination is contacted with at least one equivalent of oxygen per equivalent of activator, at least 1.5 equivalents, at least 2 equivalents, or at least 3 equivalents.
  • the oxygenated first polyolefm component/mixed catalyst system combination is then contacted with at least one second olefin monomer which may be the same or different as the first olefin monomer, in the presence of an alkyl aluminum compound, under polymerization conditions.
  • the alkyl aluminum compound is the second component of the molecular switch and serves to activate the oxygenated organochromium polymerization precatalyst.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is at least partially, preferably substantially, inactive and the organochromium polymerization catalyst is at least partially, preferably substantially, active, and produces another polyolefm component, which is different in molecular weight from the first polyolefm component.
  • the amount of second polyolefm component produced may be controlled by the amount of monomer fed to the reactor, the amount of alkyl aluminum compound, and the residence time of the second polymerization. Accordingly, a multimodal MWD polyolefm composition may be produced, with control over each mode of the polyolefm composition.
  • Polymer compositions produced by processes and mixed catalyst systems of the present invention are multimodal, having at least a first polyolefm component and another polyolefm component, which differ in molecular weight, preferably such that the GPC trace has more than one peak or inflection points.
  • Measurements of weight average molecular weight (Mw), number average molecular weight (Mn), and z average molecular weight (Mz) are determined by Gel Permeation Chromatography (GPC) as described in Macromolecules, 2001, Vol. 34, No. 19, pg. 6812, which is fully incorporated herein by reference, including that a High Temperature Size Exclusion Chromatograph (SEC, Waters Alliance 2000), equipped with a differential refractive index detector (DRI), equipped with three Polymer Laboratories PLgel 10 mm Mixed-B columns, is used. The instrument is operated with a flow rate of 1.0 cm3 /min, and an injection volume of 300 ⁇ .
  • GPC Gel Permeation Chromatography
  • the various transfer lines, columns, and differential refractometer (the DRI detector) are housed in an oven maintained at 145°C.
  • Polymer solutions are prepared by heating 0.75 to 1.5 mg/mL of polymer in filtered 1,2,4- Trichlorobenzene (TCB) containing -1000 ppm of BHT at 160°C for 2 hours with continuous agitation.
  • a sample of the polymer containing solution is injected into to the GPC and eluted using filtered 1,2,4-trichlorobenzene (TCB) containing -1000 ppm of BHT.
  • the separation efficiency of the column set is calibrated using a series of narrow MWD polystyrene standards reflecting the expected Mw range of the sample being analyzed and the exclusion limits of the column set.
  • a multimodal polyolefin composition comprising a first polyolefin component and at least another polyolefin component, different from the first polyolefin component by molecular weight, preferably such that the GPC trace has more than one peak or inflection points.
  • the nature of the multimodal polyolefin composition produced by inventive processes of the present application is illustrated by Figures 1 and 2.
  • FIG. 1 illustrates the MWD of the first polyolefin component from Example 2A (here, polyethylene) obtained from a process using a mixed catalyst system, comprising bis (l-methyl,3-butylcyclopentadienyl)zirconium dichloride and bis(cyclopentadienyl)chromium, before contact with oxygen and an alkyl aluminum compound.
  • Example 2A produced a first polyolefin component which is characteristic of those produced by metallocenes, having a low MWD, here 3.1 (See Example 2A, below).
  • FIG. 2 illustrates MWD of a multimodal polyolefin composition obtained from Example 2B (here, polyethylene) obtained from a process using a mixed catalyst system, comprising bis(l-methyl,3-butylcyclopentadienyl)zirconium dichloride and bis(cyclopentadienyl)chromium, including contact with oxygen and triethyl aluminum.
  • Example 2B polyethylene
  • a mixed catalyst system comprising bis(l-methyl,3-butylcyclopentadienyl)zirconium dichloride and bis(cyclopentadienyl)chromium, including contact with oxygen and triethyl aluminum.
  • the inventors have surprisingly discovered that another mode is observed, different from the first polyolefin component by molecular weight.
  • the new polyolefin component observed has a higher molecular weight than the first polyolefin component and the lower molecular weight tail, typically attributed to organochromium compounds, is absent.
  • MWD of the multimodal polyolefin composition is unexpectedly narrow, e.g., 4.24 (Example 2B).
  • processes herein produce a first polyolefin component having a Mw of 5,000 g/mole to 600,000 g/mole; preferably 8,000 g/mole to 400,000 g/mole; or 10,000 g/mole to 300,000 g/mole.
  • processes herein produce a first polyolefin component having a MWD of from about 1.1 to about 10, from about 2 to about 8, or from about 2.2 to about 5.
  • processes herein produce a first polyolefin component having one mode, alternately having two modes.
  • processes herein produce a first polyolefin component having a Mw of 5,000 g/mole to 600,000 g/mole; preferably 8,000 g/mole to 400,000 g/mole; or 10,000 g/mole to 300,000 g/mole; a MWD of from about 1.1 to about 10, from about 2 to about 8, or from about 2.2 to about 5; and having one mode, alternately having two modes.
  • processes herein produce a multimodal polyolefin composition comprising another polyolefin component having a Mw of 500,000 g/mole to 5,000,000 g/mole; preferably 550,000 g/mole to 2,500,000 g/mole; or 600,000 g/mole to 1,000,000 g/mole.
  • processes herein produce a multimodal polyolefin composition comprising another polyolefin component having a MWD of from about 1.1 to about 10, from about 2 to about 9, or from about 2.2 to about 6.
  • processes herein produce a multimodal polyolefin composition comprising another polyolefin component having a single mode.
  • processes herein produce a multimodal polyolefm composition
  • a multimodal polyolefm composition comprising another polyolefm component having a Mw of 500,000 g/mole to 5,000,000 g/mole; preferably 550,000 g/mole to 2,500,000 g/mole; or 600,000 g/mole to 1,000,000 g/mole; a MWD of from about 1.1 to about 10, from about 2 to about 9, or from about 2.2 to about 6; and having a single mode.
  • processes herein produce a multimodal polyolefm composition comprising less than 5 weight %, less than 2.5 weight %, or less than 1 weight %, of a component having a molecular weight less than 300,000 g/mole, less than 350,000 g/mole, or less than 375,000 g/mole.
  • the percentage of the multimodal polyolefm composition having a molecular weight less than 300,000 g/mole may be determined using techniques for isolating individual fractions of a sample of the polymeric resin. One such technique is Temperature Rising Elution Fraction (TREF), as described in Wild, et al, J. Poly. Sci., Poly. Phys. Ed., vol. 20, p.
  • TREF Temperature Rising Elution Fraction
  • a solubility distribution curve is first generated for the polymer, using data acquired from the TREF technique described above.
  • the solubility distribution curve is a plot of the weight fraction of the copolymer that is solubilized as a function of temperature. From the solubility distribution curve, the percentage of the multimodal polyolefm composition having a molecular weight less than 300,000 g/mole may be determined.
  • processes herein produce a multimodal polyolefm composition having at least two modes, or at least three modes.
  • processes herein produce a multimodal polyolefm composition
  • a first polyolefm component having a Mw of 5,000 g/mole to 600,000 g/mole; preferably 8,000 g/mole to 400,000 g/mole; or 10,000 g/mole to 300,000 g/mole; a MWD of from about 1.1 to about 10, from about 2 to about 8, or from about 2.2 to about 5; and having one mode, alternately having two modes; and
  • another polyolefm component having a Mw of 500,000 g/mole to 5,000,000 g/mole; preferably 550,000 g/mole to 2,500,000 g/mole; or 600,000 g/mole to 1,000,000 g/mole; a MWD of from about 1.1 to about 10, from about 2 to about 9, or from about 2.2 to about 6; and having a single mode; wherein the multimodal polyolefm composition: (a) has a
  • a lower molecular weight tail is characteristic in polymer obtained using organochromium catalysts or conventional mixed catalysts, such as metallocene/organochromium catalysts, and is often undesirable because the low molecular weight component may lead to poor film appearance, such as the presence of gels. Further, the presence of low molecular weight polyolefms in the multimodal polyolefin composition may lead to die-lip buildup and smoking in on-line operations.
  • the multimodal polyolefin compositions of the present invention which lack this low molecular weight tail, can be processed into films and pipe on existing equipment, and exhibit good processability in film production or for pipe applications, and may provide film product with a low gel level (excellent FQR).
  • multimodal polyolefin compositions of the present invention may have a gel level of less than 20 FQR, 30 FQR, or 40 FQR.
  • the multimodal polyolefin compositions of the present invention also may exhibit reduced tendency towards die-lip buildup and smoking in on-line operations. Accordingly, multimodal polyolefin compositions of the present invention exhibit unexpected advantages over multimodal polyolefms produced using conventional mixed catalysts such as metallocene/organochromium catalysts.
  • the catalyst may be described as a catalyst precursor, a pre-catalyst compound, or a transition metal compound, and these terms are used interchangeably.
  • a polymerization catalyst system is a catalyst system that can polymerize monomers to polymer.
  • a “catalyst system” is a combination of at least one catalyst compound, at least one activator, an optional co-activator, and a support material.
  • An "anionic ligand” is a negatively charged ligand which donates one or more pairs of electrons to a metal ion.
  • a “neutral donor ligand” is a neutrally charged ligand which donates one or more pairs of electrons to a metal ion.
  • a "substituted hydrocarbyl” is a radical made of carbon and hydrogen where at least one hydrogen is replaced by a heteroatom.
  • alkoxides include those where the alkyl group is a C ⁇ to C 10 hydrocarbyl.
  • the alkyl group may be straight chain, branched, or cyclic.
  • the alkyl group may be saturated or unsaturated. In some embodiments, the alkyl group may comprise at least one aromatic group.
  • the supported mixed catalyst system of the present invention comprises: (i) at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; (ii) an activator; (iii) at least one organochromium polymerization catalyst; and (iv) a support material; wherein under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active, the organochromium polymerization catalyst has an activity at least 50% less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal; and wherein after contact with a molecular switch, preferably comprising oxygen and an alkyl aluminum compound, and under polymerization conditions, the organochromium polymerization catalyst is at least 50% more active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal.
  • a molecular switch preferably comprising oxygen and an alkyl aluminum compound
  • each of (i) the polymerization catalyst comprising a Group 4 or Group 5 transition metal; (ii) the activator; (iii) the organochromium polymerization catalyst; and (iv) the support material, is discussed below.
  • the present invention provides a supported mixed catalyst composition
  • a polymerization catalyst comprising a Group 4 or Group 5 transition metal preferably Ti, V, Zr, or Hf; preferably Ti, Zr, or Hf; or preferably Zr or Hf.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal may be a metallocene catalyst.
  • a metallocene catalyst is defined as an organometallic compound with at least one ⁇ -bound cyclopentadienyl moiety (or substituted cyclopentadienyl moiety) and more frequently two ⁇ -bound cyclopentadienyl-moieties or substituted moieties. This includes other ⁇ -bound moieties such as indenyls or fluorenyls or derivatives thereof.
  • the polymerization catalyst comprising a Group 4 or Group 5 transition metal is represented by the formula: L A L B MX n (I);
  • M is a Group 4, or 5 transition metal, preferably M is Ti, V, Zr, or Hf; preferably Ti, Zr, or Hf; or preferably Zr or Hf;
  • the ligands, L A and L B are open, acyclic or fused ring(s) or ring system(s), including unsubstituted or substituted, cyclopentadienyl ligands, heteroatom substituted and/or heteroatom containing cyclopentadienyl ligands;
  • each X is a leaving group
  • A* is a bridging group
  • n 0, 1, 2, or 3.
  • L A and L B may be any ligand structure capable of ⁇ -bonding to M, for example cyclopentadiene, indene, fluorene, phenyl, benzyl, and the like.
  • L A and L B may comprise one or more heteroatoms, for example, nitrogen, silicon, boron, germanium, sulfur, and phosphorous, in combination with carbon atoms to form an open, acyclic, or preferably, a fused, ring or ring system, for example, a hetero- cyclopentadienyl ancillary ligand.
  • L A and L B ligands include but are not limited to amides, phosphides, alkoxides, aryloxides, imides, carbolides, borollides, porphyrins, phthalocyanines, corrins, and other polyazomacrocycles. Independently, each L A and L B may be the same or different. In one embodiment of Formula (I), only one of either L A or L B is present.
  • Each L A and L B may be independently unsubstituted or substituted with at least one R* substituent group, where substituted means that at least one (alternately at least 2, 3, 4, 5, 6, 7, 8, or 9) hydrogen group on L A and/or L B (e.g., cyclopentadiene, indene, fluorene, phenyl, benzyl, etc.) is replaced with R*.
  • substituted means that at least one (alternately at least 2, 3, 4, 5, 6, 7, 8, or 9) hydrogen group on L A and/or L B (e.g., cyclopentadiene, indene, fluorene, phenyl, benzyl, etc.) is replaced with R*.
  • Non- limiting examples of substituent groups R* include one or more from the group selected from hydrogen, or linear, or branched alkyl radicals, alkenyl radicals, alkynyl radicals, cycloalkyl radicals, aryl radicals, acyl radicals, aryl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbomoyl radicals, alkyl- or dialkyl- carbamoyl radicals, acyloxy radicals, acylamino radicals, arylamino radicals, or combination thereof.
  • substituent groups R* have up to 50 non-hydrogen atoms, preferably from 1 to 30 carbon, that may also be substituted with halogens or heteroatoms or the like.
  • alkyl substituents R* include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl groups, and the like, including all their isomers, for example, tertiary butyl, isopropyl, and the like.
  • hydrocarbyl radicals include fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl, chlorobenzyl, and hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl, and the like; and halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)silyl, methyl-bis(difluoromethyl)silyl, bromomethyldimethylgermyl, and the like; and disubstituted boron radicals including dimethylboron, for example; and disubstituted pnictogen radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine, chalcogen radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulfide, and ethy
  • Non-hydrogen substituents R* include the atoms carbon, silicon, boron, aluminum, nitrogen, phosphorous, oxygen, tin, sulfur, germanium, and the like, including olefins, such as, but not limited to, olefmically unsaturated substituents including vinyl-terminated ligands, for example, but-3- enyl, prop-2-enyl, hex-5-enyl, and the like. Also, in some embodiments, at least two R* groups, preferably two adjacent R groups, are joined to form a ring structure having from 3 to 30 atoms selected from carbon, nitrogen, oxygen, phosphorous, silicon, germanium, aluminum, boron, or a combination thereof.
  • R* may also be a diradical bonded to L at one end and forming a carbon sigma bond to the metal M.
  • Particularly preferred R* substituent groups include a C ⁇ to C 30 hydrocarbyl, a heteroatom or heteroatom containing group (preferably methyl, ethyl), propyl (including isopropyl, sec- propyl), butyl (including t-butyl and sec-butyl), neopentyl, cyclopentyl, hexyl, octyl, nonyl, decyl, phenyl, substituted phenyl, benzyl (including substituted benzyl), cyclohexyl, cyclododecyl, norbornyl, and all isomers thereof.
  • Non-limiting examples of ligands include cyclopentadienyl ligands, cyclopentaphenanthreneyl ligands, indenyl ligands, benzindenyl ligands, fluorenyl ligands, dibenzo[b,h]fluorenyl ligands, benzo[b]fluorenyl ligands, cyclooctatetraendiyl ligands, cyclopentacyclododecene ligands, azenyl ligands, azulene ligands, pentalene ligands, phosphoyl ligands, phosphinimine, pyrrolyl ligands, pyrozolyl ligands, carbazolyl ligands, boratobenzene ligands and the like, including hydrogenated versions thereof, for example tetrahydroindenyl
  • ligands may be bonded to the metal M, such as at least one leaving group X.
  • X is a monoanionic ligand bonded to M.
  • the value for n is 0, 1, 2, or 3 such that Formulae (I) and (II) above represent a neutral ligand metallocene catalyst compound.
  • Non-limiting examples of X leaving groups include weak bases, such as carboxylates, dienes, hydrocarbyl radicals having from 1 to 20 carbon atoms, hydrides or halogens, and the like, or a combination thereof.
  • two or more Xs form a part of a fused ring or ring system.
  • X ligands include those substituents for R*, as described above, and including cyclobutyl, cyclohexyl, heptyl, tolyl, trifluoromethyl, tetramethylene (both X), pentamethylene (both X), methylidene (both X), methoxy, ethoxy, propoxy, phenoxy, bis(N- methylanilide), dimethylamide, dimethylphosphide radicals, and the like.
  • X is an alkyl group or a halide.
  • X is chlorine, bromine, benzyl, phenyl, or a C ⁇ to C 12 alkyl group (such as methyl, ethyl, propyl, butyl, hexyl, and octyl).
  • the bridging group A* bridges L A and L B .
  • bridging group A* include bridging groups containing at least one Group 13 to 16 atom, often referred to as a divalent moiety, such as, but not limited to, at least one of a carbon, oxygen, nitrogen, silicon, aluminum, boron, germanium and tin atom or a combination thereof.
  • bridging group A* contains a carbon, silicon or germanium atom, most preferably, A* contains at least one silicon atom or at least one carbon atom.
  • the bridging group A* may also contain substituent groups R* as defined above including halogens and iron.
  • the bridged metallocene catalyst compounds of Formula (II) have two or more bridging groups A* (EP 664 301 Bl).
  • A* is a bridging group comprising carbon or silica, such as dialkylsilyl, preferably A* is selected from CH 2 , CH 2 CH 2 , CH(CH 3 ) 2 , SiMe 2 , SiPh 2 , SiMePh, Si(CH 2 ) 3 , (Ph) 2 CH, (p-(Et) 3 SiPh) 2 CH and Si(CH 2 ) 4 .
  • the catalyst compound is represented by Formula (III):
  • M zirconium, hafnium, vanadium, or titanium
  • the ligands, L A and L B are cyclopentadienyl, substituted cyclopentadienyl, indenyl, substituted indenyl, fluorenyl, or substituted fluorenyl;
  • each X is independently a monoanionic ligand selected from one of hydride; substituted or unsubstituted C to C 3Q hydrocarbyl; alkoxide; aryloxide; amide; halide; phosphide; and Group 14 organometalloids; or both Xs together may form an alkylidene or a cyclometallated hydrocarbyl or other dianionic ligand;
  • A* is a bridging group
  • n 0 or 1 ;
  • n 0, 1, 2, or 3.
  • L A and L B may be substituted with substituent groups R", and each group R" is, independently, a C j to C 30 hydrocarbyl, where the C j to C 30 hydrocarbyl is preferably aliphatic or aromatic.
  • R" is a C ⁇ to C 2Q hydrocarbyl, C j to C 15 hydrocarbyl, C 4 to C 30 hydrocarbyl, C 4 to C 30 hydrocarbyl, C j to C 8 hydrocarbyl and C 4 to Cg hydrocarbyl.
  • Non-limiting examples of R" include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl groups, and the like.
  • metallocene catalysts represented by Formula (IV) are useful herein.
  • M zirconium, hafnium, vanadium, or titanium
  • L A is a substituted or unsubstituted ligand bonded to M; preferentially L A is cyclopentadienyl, substituted cyclopentadienyl, indenyl, substituted indenyl, fluorenyl, or substituted fluorenyl;
  • each X is a leaving group bonded to M
  • J* is a heteroatom containing ligand bonded to M
  • A* is a bridging group
  • A* is bonded to J* and L A ;
  • n 0, 1, 2, or 3.
  • L A , A* and J* form a fused ring system.
  • J* contains a heteroatom from Group 13 to 16, preferably, nitrogen, boron, sulfur, oxygen, aluminum, silicon, phosphorous, and tin.
  • J* contains a heteroatom with a coordination number of three from Group 15 or a heteroatom with a coordination number of two from Group 16.
  • J* contains a nitrogen, phosphorus, oxygen, or sulfur atom, with nitrogen being most preferred.
  • heteroatom-containing ligand metallocene catalyst compounds are described in WO 96/33202; WO 96/34021; WO 97/17379; WO 98/22486; EP-Al-0 874 005; U.S. Patent Nos. 5,233,049; 5,539,124; 5,554,775; 5,637,660; 5,744,417; 5,756,611; and 5,856,258; all of which are incorporated herein by reference.
  • the catalyst compound is represented by Formula (V):
  • M is Zr, Hf or Ti
  • Cp is a cyclopentadienyl ring
  • J* is a Group 15 or 16 heteroatom or a substituted Group 15 or 16 heteroatom
  • each X is independently a monoanionic ligand selected from one of hydride; substituted or unsubstituted C ⁇ to C 30 hydrocarbyl; alkoxide; aryloxide; amide; halide or phosphide; Group 14 organometalloids; or both Xs together may form an alkylidene or a cyclometallated hydrocarbyl or other dianionic ligand; y is 0 or 1 ;
  • A* is a bridging group covalently bonded to both Cp and J;
  • L is an optional neutral Lewis base other than water, such as an olefin, diolefin, aryne, amine, phosphine, ether or sulfide, e.g., amines, phosphines, ethers, for example, diethylether, tetrahydrofuran, dimethylaniline, aniline, trimethylphosphine, and n-butylamine; and w is a number from 0 to 3.
  • an olefin, diolefin, aryne, amine, phosphine, ether or sulfide e.g., amines, phosphines, ethers, for example, diethylether, tetrahydrofuran, dimethylaniline, aniline, trimethylphosphine, and n-butylamine
  • w is a number from 0 to 3.
  • Cp includes cyclopentadiene ligands and their analogs capable of ⁇ -bonding to M, for example, Cp includes indene, and fluorene.
  • Cp may be substituted with from zero to five substituted groups R*, when y is zero; and from one to four substituted groups R*, when y is one; and each substituted group R* comprises, independently, a radical selected from one of hydrocarbyl, silyl-hydrocarbyl or germyl-hydrocarbyl having from 1 to 30 carbon, silicon or germanium atoms, substituted hydrocarbyl, silyl-hydrocarbyl or germyl-hydrocarbyl radicals wherein one or more hydrogen atoms may be replaced by one or more of a halogen radical, an amido radical, a phosphido radical, an alkoxy radical, an aryloxy radical or any radical containing a Lewis acidic or basic functionality; C ⁇ to C30
  • J* may be substituted with one R' group when J* is a group 15 element, and y is one, or a group 16 element and y is zero; or with two R groups when J* is a group 15 element and y is zero; or is unsubstituted when J* is a Group 16 element and y is one; and each R group is, independently, a radical selected from: hydrocarbyl, silyl- hydrocarbyl or germyl-hydrocarbyl radicals having 1 to 30 carbon, silicon or germanium atoms; substituted hydrocarbyl, silyl-hydrocarbyl or germyl-hydrocarbyl radicals wherein one or more hydrogen atoms is replaced by one or more of halogen radicals, amido radicals, phosphido radicals, alkoxy radicals, aryloxy radicals; or alkylborido radicals, preferably all Rs are bonded to J* through a primary, secondary, or aromatic carbon atom,
  • A* is as defined above, and in some embodiments, typically comprises at least one Group 13, 14, or 15 element such as carbon, silicon, boron, germanium, nitrogen, or phosphorous with additional substituents R* as defined above, so as to complete the valency of the Group 13, 14 or 15 element(s).
  • M is Ti;
  • X is chlorine, bromine, benzyl, phenyl, or a Ci to C 12 alkyl group (such as methyl, ethyl, propyl, butyl, hexyl, and octyl);
  • y is 1;
  • A* is a bridging group comprising carbon or silica, such as dialkylsilyl, preferably A* is selected from CH 2 , CH 2 CH 2 , CH(CH 3 ) 2 , SiMe 2 , SiPh 2 , SiMePh, Si(CH 2 ) 3 , (Ph) 2 CH, (p- (Et) 3 SiPh) 2 CH and Si(CH 2 ) 4 ;
  • J* is N-R', where R' is a Cj to C30 hydrocarbyl group, such as cyclododecyl, cyclohexyl, butyl (including t-butyl and sec-butyl),
  • Other particularly useful polymerization catalysts comprising a Group 4 or Group 5 transition metal include: rac-dimethyl-silyl-bis(4,5,6,7-tetrahydroindenyl)zirconium dichloride or rac-dimethyl-silyl-bis(4,5,6,7-tetrahydroindenyl)zirconium dimethyl, rac- dimethyl-silyl-bis(indenyl)zirconium dichloride or rac-dimethyl-silyl-bis(indenyl)zirconium dimethyl, rac-ethylidene-bis(4,5,6,7-tetrahydroindenyl) zirconium dichloride or rac- ethylidene-bis(4,5 ,6,7-tetrahydroindenyl)zirconium dimethyl, rac-ethylidene- bis(indenyl)zirconium dichloride or rac-ethylidene-bis(indenyl
  • Other preferred metallocenes include the unbridged metallocenes such as bis(cyclopentadienyl)zirconium dichloride, bis(cyclopentadienyl)zirconium dimethyl, bis(l,2-dimethylcyclopentadienyl)zirconium dichloride, bis(l ,2- dimethylcyclopentadienyl)zirconium dimethyl, bis(l ,3-dimethylcyclopentadienyl)zirconium dichloride, bis(l,3-dimethylcyclo-pentadienyl)zirconium dimethyl, bis(l-methyl,3- butylcyclopentadienyl)zirconium dichloride, bis(l-methyl,3-butylcyclopentadienyl)zirconium dimethyl, bis(l,2,3-trimethylcyclopentadienyl)zirconium dichloride, bis(l,2,3- trimethylcyclopentadie
  • a mixed catalyst system comprising an activator; preferably the activator activates the polymerization catalyst comprising a Group 4 or 5 transition metal.
  • the activators include alumoxanes, including modified alumoxanes, and non-coordinating anions (NCAs).
  • Alumoxanes are generally oligomeric compounds containing -Al(R!)-0- sub- units, where R 1 is an alkyl group; preferably R 1 is a methyl, ethyl, propyl, isopropyl, butyl, or isobutyl group; or more preferably R 1 is a methyl group.
  • Examples of alumoxanes include methylalumoxane (MAO), modified methylalumoxane (MMAO), ethylalumoxane and isobutylalumoxane. Mixtures of different alumoxanes and modified alumoxanes may also be used.
  • a visually clear alumoxane A cloudy or gelled alumoxane can be filtered to produce a clear solution of clear alumoxane can be decanted from the cloudy solution.
  • Another alumoxane is a modified methyl alumoxane (MMAO) cocatalyst type 3A commercially available under the trade name Modified Methylalumoxane type 3A (Akzo Chemicals, Inc., Chicago, IL), covered under U.S. Patent No. 5,041,584.
  • MMAO modified methyl alumoxane
  • the alumoxane component useful as an activator typically is an oligomeric aluminum compound represented by the general formula (R x -Al-0) n , which is a cyclic compound, or R x (R x -Al-0) n AlR x 2, which is a linear compound.
  • R x is independently a ⁇ 2 ⁇ alkyl radical, for example, methyl, ethyl, propyl, butyl, pentyl, isomers thereof, and the like, and "n" is an integer from 1-50. Most preferably, R x is methyl and "n" is at least 4.
  • Methyl alumoxane and modified methyl alumoxanes are most preferred.
  • n is 1 or 2.
  • n is 2, and m is a number from 1 to 10.
  • n is a number from 1 to 1000 preferably 1 to 100, more preferably 5 to 50, and even more preferably 5-25.
  • (x + y) the valence of M in Formula (X).
  • (x+y) the valence of M-l in Formula (XI).
  • (x+y) valence of M-2 in Formula (XII).
  • M is a Group 13 atom, preferably boron or aluminum, and more preferably aluminum.
  • (JY) represents a heterocyclic ligand attached to M.
  • the Y represents a heterocyclic ligand and J represents at least one heteroatom contained in ligand JY.
  • M may be bonded to any atom contained in Y, but is preferably bonded to heteroatom J.
  • J is an atom selected from Group 15 or 16, more preferably J is nitrogen, oxygen, or sulfur, and most preferably J is nitrogen.
  • Non-limiting examples of (JY) include pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, purinyl, carbazolyl, and indolyl groups.
  • the heterocyclic ligand (JY) may be unsubstituted or substituted with one or a combination of substituent groups.
  • suitable substituents include hydrogen, halogen, linear or branched alkyl, alkenyl or alkynyl radicals, cycloalkyl radicals, aryl radicals, aryl substituted alkyl radicals, acyl radicals, aroyl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbomoyl radicals, alkyl- or dialkyl-carbamoyl radicals, acyloxy radicals, acylamino radicals, aroylamino radicals, straight, branched or cyclic, alkylene radicals, or combination thereof.
  • the substituent groups may also be substituted with halogens, particularly fluorine, or heteroatoms,
  • Non- limiting examples of substituents include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl groups, and the like, including all their isomers, for example, tertiary butyl, isopropyl, and the like.
  • substituents include fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl, and chlorobenzyl.
  • one or more positions on the heterocyclic ligand (JY) is substituted with a halogen atom or a halogen atom containing group, preferably the halogen is chlorine, bromine or fluorine, more preferably bromine or fluorine, and most preferably fluorine. Even more preferably, the substituent is a fluorine atom or a fluorinated aryl group, such as a fluorinated phenyl group.
  • Each R' is independently a substituent group bonded to M.
  • substituent R' groups include hydrogen, linear or branched alkyl or alkenyl radicals, alkynyl radicals, cycloalkyl radicals, aryl radicals, acyl radicals, aroyl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbomoyl radicals, alkyl- or dialkyl-carbamoyl radicals, acyloxy radicals, acylamino radicals, aroylamino radicals, straight, branched or cyclic alkylene radicals, or combination thereof.
  • Each R may be a methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl group, including all their isomers, for example tertiary butyl, isopropyl, and the like.
  • R substituents may include hydrocarbyl radicals, such as fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl, chlorobenzyl; hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl, and the like; halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)-silyl, methyl- bis(difluoromethyl)silyl, bromomethyldimethylgermyl, and the like; disubstituted boron radicals including dimethylboron, for example; disubstituted pnictogen radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine; and chalcogen radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulf
  • R' substituents may include the atoms carbon, silicon, boron, aluminum, nitrogen, phosphorous, oxygen, tin, sulfur, or germanium, and the like.
  • Substituent R groups also include olefins, such as, but not limited to, olefmically unsaturated substituents including vinyl-terminated ligands, for example but-3-enyl, prop-2-enyl, hex-5-enyl, and the like.
  • at least two R groups, preferably two adjacent R groups may be joined to form a ring structure having from 3 to 30 atoms selected from carbon, nitrogen, oxygen, phosphorous, silicon, germanium, aluminum, boron, or a combination thereof.
  • each R is a substituted or unsubstituted alkyl group and/or a substituted or unsubstituted aryl group, and preferably each R' is an alkyl group containing 1 to 30 carbon atoms.
  • M is Al or B, preferably Al
  • J is a nitrogen atom contained in heterocyclic ligand Y
  • (JY) is a substituted or unsubstituted indolyl group where the substituents are preferably hydrogen, halogen, an alkyl group, a halogenated or partially halogenated alkyl group, an aryl group, a halogenated or partially halogenated aryl group, an aryl substituted alkyl group, a halogenated or partially halogenated aryl substituted alkyl group, or combinations thereof, preferably J is bound to M, and R' a substituted or unsubstituted alkyl group and/or a substituted or unsubstituted aryl group, preferably an alkyl group containing 1 to 30 carbon atoms.
  • M is Al or B, preferably Al, J is a nitrogen atom bonded to M and contained in a heterocyclic ligand Y where the heterocyclic ligand (JY) is an unsubstituted heterocyclic ligand.
  • one or more positions on the heterocyclic ligand is substituted with chlorine, bromine, and/or fluorine or with chlorine, bromine and/or fluorine containing groups, more preferably with fluorine or fluorine containing groups
  • R is a substituted or unsubstituted alkyl group and/or a substituted or unsubstituted aryl group, preferably an alkyl group containing 1 to 30 carbon atoms.
  • (JY) is a perhalogenated ligand.
  • M is Al or B, preferably Al
  • J is a nitrogen atom bonded to M and contained in a heterocyclic ligand Y where the heterocyclic ligand (JY) is an unsubstituted heterocyclic ligand.
  • one or more positions on the heterocyclic group is substituted with a halogen such as chlorine, bromine and/or fluorine atoms, or with a halogen atom, such as a chlorine, bromine, and/or fluorine containing groups. More preferably the heterocyclic group is substituted with fluorine or fluorine containing groups.
  • at least one R is bonded to a support material, preferably a silica support material.
  • the minimum activator-to-transition metal (polymerization catalyst comprising a Group 4 or Group 5 transition metal) ratio is a 1 : 1 molar ratio.
  • Alternate preferred ratios include up to 5000: 1, preferably up to 500: 1, preferably up to 200: 1, preferably up to 100: 1, or preferably from 1 : 1 to 50: 1.
  • NCA activators are NCA activators.
  • non-coordinating anion is defined to mean an anion which either does not coordinate to the catalyst metal cation or that coordinates only weakly to the metal cation.
  • An NCA coordinates weakly enough that a neutral Lewis base, such as an olefmically or acetylenically unsaturated monomer, can displace it from the catalyst center.
  • Any metal or metalloid that can form a compatible, weakly coordinating complex with the catalyst metal cation may be used or contained in the noncoordinating anion. Suitable metals include, but are not limited to, aluminum, gold, and platinum.
  • Suitable metalloids include, but are not limited to, boron, aluminum, phosphorus, and silicon.
  • a subclass of NCAs comprises stoichiometric activators, which can be either neutral or ionic.
  • ionic activator and “stoichiometric ionic activator” can be used interchangeably.
  • neutral stoichiometric activator and “Lewis acid activator” can also be used interchangeably.
  • an ionizing or stoichiometric activator such as tri (n-butyl) ammonium tetrakis (pentafluorophenyl) borate, a tris perfluorophenyl boron metalloid precursor, or a tris perfluoronapthyl boron metalloid precursor, polyhalogenated heteroborane anions (WO 98/43983), boric acid (U.S. Patent No. 5,942,459), or a combination thereof.
  • the activator is ⁇ , ⁇ -dimethylanilinium tetrakis(perfluoronapthyl) borate, ⁇ , ⁇ -dimethylanilinium tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triphenylcarbeniumtetrakis(perfluoronapthyl) borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluorophenyl) borate, or ⁇ , ⁇ -dimethylanilinium tetrakis(pentafluorophenyl)borate.
  • the more preferred activator is ⁇ , ⁇ -dimethylanilinium tetrakis(pentafluorophenyl)borate.
  • ⁇ , ⁇ -dimethylanilinium tetrakis(pentafluorophenyl)borate for additional activators useful herein, please see U.S. Patent Publication No. 2009-0318644.
  • Metal oxide support bound activators such as those disclosed in WO/1996/004319, are also useful in embodiments herein.
  • the typical NCA activator-to-transition metal (total moles of transition metal in mixed catalyst system, that is sum of the number of moles of Group 4 or Group 5 transition metal and chromium) ratio is a 1 : 1 molar ratio.
  • Alternate preferred ranges include from 0.1 : 1 to 100: 1, alternately from 0.5: 1 to 200: 1, alternately from 1 : 1 to 500: 1 alternately from 1 : 1 to 1000: 1.
  • a particularly useful range is from 0.5: 1 to 10: 1, preferably 1 : 1 to 5: 1.
  • organochromium polymerization catalyst Any organochromium polymerization catalyst may be used.
  • organochromium polymerization catalysts useful in the present invention have one of the following formulae:
  • L A and L B are independently selected from cyclopentadienyl, substituted cyclopentadienyl, indenyl, substituted indenyl, fluorenyl, or substituted fluorenyl;
  • each X is, independently, N, O, P or S, preferably N; each n is independently 1 or 2; m is 1 or 2; and each R is, independently, an alkyl group, a substituted alkyl group, an aryl group, or a substituted aryl group, provided at least one R group is an aryl or substituted aryl group; preferably each R is selected from the group consisting of substituted or unsubstituted phenyl, naphthyl, biphenyl, diphenylether, tolyl, or benzophenonephenyl; more preferably each R group is selected from the group consisting of napthyl, phenyl, biphenyl, fluorophenyl, and tolyl.
  • organochromium polymerization catalysts include: bisbenzene chromium(O); dicumene chromium(O); bis(mesitylene chromium(O); biscyclopentadienylchromium (chromocene); bis(methylcyclopentadienyl)chromium(II); bis(l ,3-bis(trimethylsilyl)allyl) chromium(II); bis(trimethylsilylmethyl) chromium(II);
  • Exemplary organochromium polymerization catalysts useful in this invention also include, the following compounds: (r
  • organochromium polymerization catalysts include, dicumene chromium(O), bisbenzene chromium(O), and chromocene.
  • the organochromium polymerization catalysts include Cr(III)(N(SiMe 3 ) 2 )3, Cr(III)(NPh 2 ) 3 , and Cr(III)(N(SiMe 3 ) 2 ) 2 .
  • the mixed catalyst system may comprise an inert support material.
  • the supported material is a porous support material, for example, talc, and inorganic oxides.
  • Other support materials include zeolites, clays, organoclays, or any other organic or inorganic support material and the like, or mixtures thereof.
  • the support material is an inorganic oxide in a finely divided form.
  • Suitable inorganic oxide materials for use in metallocene catalyst systems herein include Groups 2, 4, 13, and 14 metal oxides such as silica, alumina, and mixtures thereof.
  • Other inorganic oxides that may be employed either alone or in combination with the silica, or alumina are magnesia, titania, zirconia, and the like.
  • Other suitable support materials can be employed, for example, finely divided functionalized polyolefins such as finely divided polyethylene.
  • Particularly useful supports include magnesia, titania, zirconia, montmorillonite, phyllosilicate, zeolites, talc, clays, and the like. Also, combinations of these support materials may be used, for example, silica-chromium, silica-alumina, silica-titania, and the like.
  • Preferred support materials include A1 2 0 3 , Zr0 2 , Si0 2 , and combinations thereof, more preferably Si0 2 , A1 2 0 3 , or Si0 2 /Al 2 0 3 .
  • the support material most preferably an inorganic oxide, has a surface area in the range of from about 10 to about 700 m 2 /g, pore volume in the range of from about 0.1 to about 4.0 cc/g and average particle size in the range of from about 5 to about 500 ⁇ . More preferably, the surface area of the support material is in the range of from about 50 to about 500 m 2 /g, pore volume of from about 0.5 to about 3.5 cc/g and average particle size of from about 10 to about 200 ⁇ .
  • the surface area of the support material is in the range is from about 100 to about 400 m 2 /g, pore volume from about 0.8 to about 3.0 cc/g and average particle size is from about 5 to about 100 um.
  • the average pore size of the support material useful in the invention is in the range of from 10 to 1000 A , preferably 50 to about 500 A , and most preferably 75 to about 350 A .
  • the support material should be dry, that is, free of absorbed water. Drying of the support material can be effected by heating or calcining at about 100°C to about 1000°C, preferably at least about 600°C. When the support material is silica, it is heated to at least 200°C, preferably about 200°C to about 850°C, and most preferably at about 600°C; and for a time of about 1 minute to about 100 hours, from about 12 hours to about 72 hours, or from about 24 hours to about 60 hours.
  • the calcined support material must have at least some reactive hydroxyl (OH) groups to produce the catalyst system of this invention.
  • the calcined support material is then contacted with at least one polymerization catalyst comprising a Group 4 or Group 5 transition metal and at least one activator, as discussed above.
  • This invention encompasses a mixed catalyst composition
  • a mixed catalyst composition comprising the contact product of (i) a polymerization catalyst comprising a Group 4 or Group 5 transition metal, (ii) an activator, (iii) an organochromium polymerization catalyst, and (iv) a support material, each component of which was discussed above.
  • This invention further relates to a method of making a supported mixed catalyst system comprising: (i) contacting a support material with a polymerization catalyst comprising a Group 4 or Group 5 transition metal and an activator, such that the reactive groups on the support material are titrated, to form a supported polymerization catalyst; (ii) thereafter contacting the supported polymerization catalyst with an organochromium polymerization catalyst to form a supported mixed catalyst system; wherein the organochromium polymerization catalyst and polymerization catalyst comprising a Group 4 or Group 5 transition metal differ in molecular switch response by at least 50%; and wherein the organochromium polymerization catalyst of the supported mixed catalyst system is less active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal by at least 50%, under polymerization conditions where the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active.
  • the support material is contacted with a solution of a polymerization catalyst comprising a Group 4 or Group 5 transition metal and an activator, such that the reactive groups on the support material are titrated, to form a supported polymerization catalyst.
  • the period of time for contact between the polymerization catalyst comprising a Group 4 or Group 5 transition metal, an activator compound, and the support material is as long as is necessary to titrate the reactive groups on the support material.
  • titrate is meant to react with available reactive groups on the surface of the support material, thereby reducing the surface hydroxyl groups by at least 80%, at least 90%, at least 95%, or at least 98%.
  • the surface reactive group concentration may be determined based on the calcining temperature and the type of support material used.
  • the support material calcining temperature affects the number of surface reactive groups on the support material available to react with the polymerization catalyst comprising a Group 4 or Group 5 transition metal and an activator: the higher the drying temperature, the lower the number of sites.
  • the support material is silica which, prior to the use thereof in the first catalyst system synthesis step, is dehydrated by fluidizing it with nitrogen and heating at about 600°C for about 16 hours
  • mmols/gm millimoles per gram
  • the exact molar ratio of the activator to the surface reactive groups on the carrier will vary. Preferably, this is determined on a case-by-case basis to assure that only so much of the activator is added to the solution as will be deposited onto the support material without leaving excess of the activator in the solution.
  • the amount of the activator which will be deposited onto the support material without leaving excess in the solution can be determined in any conventional manner, e.g., by adding the activator to the slurry of the carrier in the solvent, while stirring the slurry, until the activator is detected as a solution in the solvent by any technique known in the art, such as by 3 ⁇ 4 NMR.
  • the amount of the activator added to the slurry is such that the molar ratio of Al to the hydroxyl groups (OH) on the silica is about 0.5: 1 to about 4: 1, preferably about 0.8: 1 to about 3: 1, more preferably about 0.9: 1 to about 2: 1 and most preferably about 1 : 1.
  • the amount of Al on the silica may be determined by using ICPES (Inductively Coupled Plasma Emission Spectrometry), which is described in J. W. Olesik, "Inductively Coupled Plasma-Optical Emission Spectroscopy," in the Encyclopedia of Materials Characterization, C. R. Brundle, C. A. Evans, Jr. and S. Wilson, eds., Butterworth-Heinemann, Boston, Mass., 1992, pp. 633- 644.
  • ICPES Inductively Coupled Plasma Emission Spectrometry
  • the support material having reactive surface groups, typically hydroxyl groups, is slurried in a non-polar solvent and the resulting slurry is contacted with a solution of a polymerization catalyst comprising a Group 4 or Group 5 transition metal and an activator.
  • the slurry of the support material in the solvent is prepared by introducing the support material into the solvent, and heating the mixture to about 0°C to about 70°C, preferably to about 25°C to about 60°C, preferably at room temperature.
  • Contact times typically range from about 0.5 hours to about 24 hours, from about 2 hours to about 16 hours, or from about 4 hours to about 8 hours.
  • Suitable non-polar solvents are materials in which all of the reactants used herein, i.e., the activator, and the polymerization catalyst comprising a Group 4 or Group 5 transition metal, are at least partially soluble and which are liquid at reaction temperatures.
  • Preferred non-polar solvents are alkanes, such as isopentane, hexane, n-heptane, octane, nonane, and decane, although a variety of other materials including cycloalkanes, such as cyclohexane, aromatics, such as benzene, toluene and ethylbenzene, may also be employed.
  • the supported polymerization catalyst is thereafter contacted with the first organochromium polymerization catalyst to form a supported mixed catalyst system.
  • the period of time for contact between the supported polymerization catalyst and the organochromium catalyst typically ranges from about 0.5 hours to about 24 hours, from about 2 hours to about 16 hours, or from about 4 hours to about 8 hours.
  • the mixture may be heated from between about 10°C to about 200°C, from about 20°C to about 95°C, preferably the mixture is not heated during the contacting time.
  • the molar ratio of the polymerization catalyst comprising a Group 4 or a Group 5 transition metal to the organochromium polymerization catalyst may be from about 100: 1 to about 1 : 100, from about 10: 1 to about 1 : 10, or from about 5: 1 to about 1 :5.
  • the molar ratio of the polymerization catalyst comprising a Group 4 or a Group 5 transition metal to the activator compound may be from about 1 : 100 to about 1 : 1, from about 1 : 100 to about 1 :5, and from about 1 :50 to about 1 : 10.
  • the weight ratio of the polymerization catalyst comprising a Group 4 or a Group 5 transition metal to the solid support material may be from about 10: 1 to about 0.0001 : 1, from about 1 : 1 to about 0.001 : 1, or from about 0.1 : 1 to about 0.001 :1.
  • the weight ratio of the support material to the activator compound may range from about 1 : 10 to about 100: 1, from about 1 : 1 to about 100:1, or from about 1 : 1 to about 10: 1.
  • the pre-prepared or commercially available supported polymerization catalyst comprising a Group 4 or Group 5 transition metal and an activator to form the mixed catalyst systems of the present invention, as long the reactive groups on the support material have been titrated.
  • the pre-prepared or commercially available supported polymerization catalyst is contacted with the first organochromium polymerization catalyst to form a mixed catalyst system.
  • the period of time for contact between the pre-prepared or commercially available supported polymerization catalyst and the organochromium catalyst typically ranges from about 0.5 hours to about 24 hours, from about 2 hours to about 16 hours, or from about 4 hours to about 8 hours.
  • the mixture may be heated from between about 10°C to about 200°C, from about 20°C to about 95°C, preferably the mixture is not heated during the contacting time.
  • Using a pre-prepared or a commercially available supported polymerization catalyst is advantageous because it allows easier screening of mixed catalysts, is more efficient, and saves time.
  • this invention further relates to a method of making a supported mixed catalyst system comprising: (i) contacting a support material with a polymerization catalyst comprising a Group 4 or Group 5 transition metal and an activator, such that the weight ratio of the polymerization catalyst comprising a Group 4 or a Group 5 transition metal to the solid support material is in the range of from about 10: 1 to about 0.0001 : 1, from about 1 : 1 to about 0.001 : 1, or from about 0.1 : 1 to about 0.001 : 1; and the weight ratio of the support material to the activator compound is in the range of from about 1 : 10 to about 100: 1, from about 1 : 1 to about 100: 1, or from about 1 : 1 to about 10: 1 such that the reactive groups on the support material are titrated, for a time period of from about 0.5 hours to about 24 hours, from about 2 hours to about 16 hours, or from about 4 hours to about 8 hours; at a temperature from between about 10°C to about 200°
  • this invention relates to:
  • a process to make a multimodal polyolefin composition comprising:
  • At least one polymerization catalyst comprising a Group 4 or Group 5 transition metal; preferably zirconium, hafnium, titanium, or vanadium; preferably zirconium, hafnium, or titanium; preferably zirconium or hafnium; or more preferably a metallocene represented by the formula:
  • M is a Group 4 or 5 transition metal
  • the ligands, L A and L B are open, acyclic or fused ring(s) or ring system(s), including unsubstituted or substituted, cyclopentadienyl ligands, heteroatom substituted and/or heteroatom containing cyclopentadienyl ligands;
  • each X is a leaving group
  • A* is a bridging group
  • n 0, 1, 2, or 3;
  • R is a Ci to C 2 o hydrocarbyl group
  • n is selected from 2, 3, and 4;
  • n 1 or 2;
  • each R is, independently, an alkyl group, a substituted alkyl group, an aryl group, or a substituted aryl group, provided at least one R group is an aryl or substituted aryl group;
  • an activator preferably an alumoxane
  • a first polyolefm component having a Mw of 5,000 g/mol to 600,000 g/mol, preferably 8,000 g/mole to 400,000 g/mole; or 10,000 g/mole to 300,000 g/mole; a Mw/Mn of greater than 1 to about 10; and having at least one mode; and
  • (ii) comprises less than 5 weight %, of a component having a molecular weight less than 300,000 g/mole;
  • step (iii) has a multimodal molecular weight distribution, having preferably two modes, or preferably three modes. 2. The process of paragraph 1, wherein under polymerization conditions for step (i), the polymerization catalyst comprising a Group 4 or Group 5 transition metal is active and the organochromium polymerization catalyst has an activity at least 50% less than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal.
  • the organochromium polymerization catalyst has an activity at least 50% greater than the activity of the polymerization catalyst comprising a Group 4 or Group 5 transition metal.
  • a molecular switch preferably the molecular switch comprises oxygen and an alkyl aluminum compound
  • a method of making the supported mixed catalyst system of paragraph 9 comprising:
  • organochromium polymerization catalyst of the supported mixed catalyst system is less active than the polymerization catalyst comprising a Group 4 or Group 5 transition metal by at least 50%, under polymerization conditions of step (i).
  • Bis(cyclopentadienyl)chromium was purchased from Strem Chemicals (Newburyport, MA) and was used as received.
  • a 30 wt% methyl aluminoxane (MAO) in toluene solution and bis(l -methyl, 3 -butyl cyclop entadienyl) zirconium dichloride were purchased from Albemarle (Baton Rouge, LA) and was used as received.
  • Triethylaluminum and triisobutylaluminum were purchased from AkzoNobel (Chicago, IL) and used as received.
  • Toluene was purchased from Sigma Aldrich (St. Louis, MO) and dried with previously calcined alumina beads.
  • compositions encompasses the terms “consisting essentially of,” “is,” and “consisting of and anyplace “comprising” is used “consisting essentially of,” “is,” or “consisting of may be substituted therefore.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)

Abstract

Cette invention concerne un procédé de production d'une composition de polyoléfine multimodale comprenant : (i) la mise en contact d'au moins un premier monomère d'oléfine avec un système de catalyseurs mixte, dans des conditions de polymérisation, pour obtenir au moins un premier composant de polyoléfine ayant un poids Mw de 5000 à 600 000 g/mol, le système de catalyseurs mixte comprenant : (a) au moins un catalyseur de polymérisation à base d'un métal de transition du Groupe 4 ou du Groupe 5; (b) au moins un catalyseur de polymérisation à base de chrome organique; (c) un activateur; et (d) un matériau de support; (ii) puis, la mise en contact de la combinaison premier composant de polyoléfine/système de catalyseurs mixte avec un commutateur moléculaire; (iii) la mise en contact de la combinaison premier composant de polyoléfine/système de catalyseurs mixte avec au moins un second monomère d'oléfine, qui peut être identique ou différent, dans des conditions de polymérisation; et (iv) l'obtention d'une composition de polyoléfine multimodale.
EP11841727.8A 2010-11-19 2011-10-26 Procédés de production de polyoléfines ayant une distribution des poids moléculaires multimodale Withdrawn EP2640757A4 (fr)

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EP11841727.8A EP2640757A4 (fr) 2010-11-19 2011-10-26 Procédés de production de polyoléfines ayant une distribution des poids moléculaires multimodale

Applications Claiming Priority (4)

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US12/950,501 US8148470B1 (en) 2010-11-19 2010-11-19 Processes for making multimodal molecular weight distribution polyolefins
EP10196508 2010-12-22
PCT/US2011/057832 WO2012067777A2 (fr) 2010-11-19 2011-10-26 Procédés de production de polyoléfines ayant une distribution des poids moléculaires multimodale
EP11841727.8A EP2640757A4 (fr) 2010-11-19 2011-10-26 Procédés de production de polyoléfines ayant une distribution des poids moléculaires multimodale

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WO2006069204A2 (fr) * 2004-12-21 2006-06-29 Univation Technologies, Llc Procede de transition entre des catalyseurs de type ziegler-natta et des catalyseurs a base de chrome
US7163906B2 (en) * 2004-11-04 2007-01-16 Chevron Phillips Chemical Company, Llp Organochromium/metallocene combination catalysts for producing bimodal resins

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US5795941A (en) * 1995-10-03 1998-08-18 The Dow Chemical Company Crosslinkable bimodal polyolefin compositions
NO980552D0 (no) * 1998-02-09 1998-02-09 Borealis As Katalysatorbestandel og katalysator for (ko)polymerisering av etylen, og fremgangsmåte for fremstilling av slik
JP2008519092A (ja) * 2004-11-04 2008-06-05 シェブロン フィリップス ケミカル カンパニー エルピー 双峰型樹脂を製造するための有機クロム／メタロセン併用触媒
DE102005056775A1 (de) * 2005-11-28 2007-05-31 Basell Polyolefine Gmbh Verfahren für den Katalysatorwechsel in einem Gasphasenwirbelschichtreaktor
CA2529920C (fr) * 2005-12-13 2013-08-20 Nova Chemicals Corporation Transitions de catalyseurs dans la lancee

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US7163906B2 (en) * 2004-11-04 2007-01-16 Chevron Phillips Chemical Company, Llp Organochromium/metallocene combination catalysts for producing bimodal resins
WO2006069204A2 (fr) * 2004-12-21 2006-06-29 Univation Technologies, Llc Procede de transition entre des catalyseurs de type ziegler-natta et des catalyseurs a base de chrome

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EP2640757A4 (fr) 2014-07-30
CN103052655A (zh) 2013-04-17
RU2013122566A (ru) 2014-11-27
MY165619A (en) 2018-04-18
RU2579518C2 (ru) 2016-04-10
CN103052655B (zh) 2015-05-13
WO2012067777A3 (fr) 2012-07-12
WO2012067777A2 (fr) 2012-05-24
BR112013002457A2 (pt) 2017-03-21
BR112013002457B1 (pt) 2022-04-26

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