Classifications

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  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
  • C10M107/02—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation
  • C10M107/10—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation containing aliphatic monomer having more than 4 carbon atoms
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • B01J31/26—Catalysts comprising hydrides, coordination complexes or organic compounds containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24
  • B01J31/38—Catalysts comprising hydrides, coordination complexes or organic compounds containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24 of titanium, zirconium or hafnium
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  • 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
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  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G50/00—Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation
  • C10G50/02—Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation of hydrocarbon oils for lubricating purposes
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  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M141/00—Lubricating compositions characterised by the additive being a mixture of two or more compounds covered by more than one of the main groups C10M125/00 - C10M139/00, each of these compounds being essential
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
  • B01J31/18—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms
  • B01J31/1805—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms the ligands containing nitrogen
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
  • B01J31/22—Organic complexes
  • B01J31/2282—Unsaturated compounds used as ligands
  • B01J31/2295—Cyclic compounds, e.g. cyclopentadienyls
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
  • B01J31/26—Catalysts comprising hydrides, coordination complexes or organic compounds containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24
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  • 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
  • C08F110/14—Monomers containing five or more carbon atoms
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/6592—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
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1088—Olefins
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/70—Catalyst aspects
  • C10G2300/703—Activation
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
  • C10G2400/10—Lubricating oil
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
  • C10M2205/02—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
  • C10M2205/02—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers
  • C10M2205/0206—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers used as base material
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
  • C10M2205/02—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers
  • C10M2205/028—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers containing aliphatic monomers having more than four carbon atoms
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
  • C10N2020/01—Physico-chemical properties

Definitions

• the present invention relates generally to a multistep preparation of an oligomer oil, and relates more particularly to an aforesaid multistep preparation in which the first step involves the polymerization of a feedstock containing one or more C 3 to C 20 1-olefins in the presence of a catalyst comprising a bulky ligand transition metal catalyst and in which a subsequent step involves the oligomerization of at least a preselected fraction of the product of the first step.
• the catalyst system also includes an activator compound containing a metal of Group II or III of the Periodic Table of the Elements, especially trialkyl aluminum compounds, alumoxanes both linear and cyclic, or ionizing ionic activators or compounds such as tri(n-butyl) ammonium tetra(pentafluorophenyl) boron.
• the disclosed process involves copolymerization of ethylene and an alpha-olefin. Suitable alpha-olefins have one hydrogen atom on the second carbon, at least two hydrogens on the third carbon or at least one hydrogen on the fourth carbon.
• the resulting copolymers produced contain a high degree of terminal ethenylidene or vinylidene unsaturation, and have a number average molecular weight of 300 to 15,000 and a molecular weight distribution (W ⁇ JMschreib) of typically less than 5.
• U.S. Patent No. 5,688,887 discloses another such process for polymerizing a feedstock containing one or more C 3 to C 20 1-olefins and a second hydrocarbon which is not a 1 -olefin, to form a highly reactive, low molecular weight, viscous, essentially -1-olef ⁇ n-containing poly( 1-olefin) or copoly(1 -olefin) in the presence of a metallocene catalyst comprising a cyclopentadienyl or indenyl Periodic Group IVb metallocene catalyst and aluminoxane cocatalyst.
• a metallocene catalyst comprising a cyclopentadienyl or indenyl Periodic Group IVb metallocene catalyst and aluminoxane cocatalyst.
• the resulting polymer product has a terminal vinylidene content of more than 80%, is highly reactive and has a molecular weight between 300 and 10,000. Bagheri et al. also discloses reactions of the poly( 1-olefin) or copoly(1 -olefin) product in which the terminal vinylidene linkage is reacted with an aromatic, an epoxidation agent, a silylation agent, maleic anhydride, carbon monoxide and hydrogen, halogen and hydrohalogen.
• oligomer oils from vinyl olefins A major problem associated with making oligomer oils from vinyl olefins is that the oligomer product mix usually must be fractionated into different portions to obtain oils of a given desired viscosity (e.g., 2, 4, 6 or 8 cSt at 100°C). As a result, in commercial production it is difficult to obtain an oligomer product mix which, when fractionated, will produce the relative amounts of each viscosity product which correspond to market demand, and it is often necessary to produce an excess of one product in order to obtain the needed amount of the other. Another problem is the lack of control over the chemistry, and isomerization of alpha olefins to internal olefins.
• a third problem is that polymerization processes often yield a high percentage of dimer, which is unsuitable (too volatile) for use as a lubricant. Therefore, it is highly desirable to develop a process that provides the versatility of allowing the viscosity of the product to be tailored with improved selectivity and product oils having a pre-selected desired viscosity to be manufactured reproducibly and easily.
• Schaerfl et al. U.S. Patents Nos. 5,284,988 and 5,498,815 disclose two two- step processes for preparing a synthetic oil that do provide improved versatility of allowing one to tailor the viscosity of the synthetic oil product with improved selectivity.
• U.S. Patent No. 5,284,988 discloses a process which provides improved selectivity when forming synthetic oils using as starting olefins, vinylidene olefins and alpha-olefins.
• the process of U.S. Patent No. 5,284,988 for making a synthetic oil comprises (a) isomerizing at least a portion of a vinylidene olefin feed in the presence of an isomerization catalyst to form an intermediate which contains tri-substituted olefin and (b) codimerizing the intermediate and at least one vinyl olefin in the presence of an oligomerization catalyst to form a synthetic oil which comprises a co- dimer of the vinylidene olefin and the vinyl olefin.
• Suitable vinylidene olefins for use in the isomerization step of the process of U.S. PaterTt No. 5,284,988 can be prepared using known methods such as by dimerizing vinyl olefins containing from 4 to about 30 carbon atoms, preferably at least 6, and most preferably at least 8 to about 20 carbon atoms, including mixtures thereof.
• Suitable vinyl olefins for use in the codimerization step of the process of U.S. Patent No. 5,284,988 contain from 4 to about 30 carbon atoms, and, preferably about 6 to about 24 carbon atoms, including mixtures thereof.
• the codimerization step can use any suitable dimerization catalyst known in the art and especially Friedel-Crafts type catalysts such as acid halides (Lewis Acid) or proton acid (Bronsted Acid) catalysts, which can be used in combination and with promoters.
• Friedel-Crafts type catalysts such as acid halides (Lewis Acid) or proton acid (Bronsted Acid) catalysts, which can be used in combination and with promoters.
• U.S. Patent No. 5,498,815 discloses a process for making a synthetic oil which comprises the steps of reacting a vinylidene olefin in the presence of a catalyst to form an intermediate mixture which contains at least about 50 weight percent dimer of the vinylidene olefin, and thereafter adding a vinyl olefin to the intermediate mixture and reacting the intermediate mixture and the vinyl olefin in the presence of a catalyst so as to form a product mixture which contains the dimer of the vinylidene olefin and a co-dimer of the added vinyl olefin with the vinylidene olefin.
• Suitable vinylidene olefins for use in the first step of this process can be prepared using known methods, such as by dimerizing vinyl olefins containing from 4 to about 30 carbon atoms.
• Suitable vinyl olefins for use in the second step of this process contain from 4 to about 30 carbon atoms. Both steps can use any suitable dimerization catalyst known in the art and especially Friedel-Crafts type catalysts such as acid halides (Lewis Acid) or proton acid (Bronsted Acid) catalysts, which catalysts can be used in combination and with promoters.
• the alpha-olefin oligomers are obtained by oligomerization of C 6 to C 20 alpha-olefin feedstock in the presence of a reduced valence state Group VIB metal catalyst on a porous support and recovering from the resulting product mixture oligomers comprising olefinic * lubricant range hydrocarbons.
• a reduced valence state Group VIB metal catalyst on a porous support
• 5,498,815 nor PCT/US90/00863 discloses a multistep process that involves in the first step the polymerization of an olefin in the presence of a catalyst system comprising a bulky ligand transition metal complex to form a product mixture comprising a distribution of products at least a fraction of which have properties that are outside of a predetermined range therefor, and in a subsequent step the oligomerization of at least a pre-selected fraction of the product mixture formed in the first step.
• a catalyst system comprising a bulky ligand transition metal complex of the Formula 1 and an activating quantity of an activator comprising an organoaluminum compound or a hydrocarbylboron compound or a mixture thereof:
• L is the bulky ligand
• M is the transition metal
• X and X 1 may be the same or different and are independently selected from the group consisting of halogen, hydrocarbyl group or hydrocarboxyl group having 1-20 carbon atoms
• m is 1-3
• n is 0-3
• p is 0-3
• the sum of the integers m + n + p corresponds to the transition metal valency.
• a product mixture is formed that comprises a distribution of products at least a fraction of which have properties that are outside of a predetermined range therefor.
• a subsequent step (b) at least a pre-selected fraction of the product formed in step (a) is oligomerized in the presence of an acidic oligomerization catalyst to thereby form the aforesaid oligomer oil.
• the catalyst system employed in step (a) of the method of this invention comprises a bulky ligand transition metal complex of the stoichiometric Formula 1 :
• L is the bulky ligand
• M is the transition metal
• X and X 1 are independently selected from the group consisting of halogen, hydrocarbyl group or hydrocarboxyl group having 1-20 carbon atoms
• m is 1-3
• n is 0-3
• p is 0-3
• the sum of the integers m + n + p corresponds to the transition metal valency.
• the aforesaid metal complex contains a multiplicity of bonded atoms forming a group which may be cyclic with one or more optional heteroatoms.
• the ligands L and X may be bridged to each other, and if two ligands L and/or X are present, they may be bridged.
• the catalyst is a metallocene
• M is a Group IV, V or VI transition metal
• one or more L is a cyclopentadienyl or indenyl moiety.
• the feed comprises one or more linear C 3 to C 20 1-oTefins
• the product mixture formed in step (a) comprises an essentially terminally unsaturated viscous, essentially 1-olefin-containing poly( 1-olefin) or copoly( 1-olefin) of molecular weight between 300 and 10,000 that exhibits a terminal vinylidene content of more than 50%, preferably more than 80%.
• the metallocene is represented by the stoichiometric Formula 2:
• each Cp is a substituted or unsubstituted cyclopentadienyl or indenyl ring, and each such substituent thereon can be the same or different and is an alkyl, alkenyl, aryl, alkaryl, or aralkyl radical having from 1 to 20 carbon atoms or at least two carbon atoms formed together to form a part of a C 4 or C 6 ring; wherein R 1 and R 2 are independently selected from the group consisting of halogen, hydrocarbyl, hydrocarboxyl, each having 1-20 carbon atoms; and wherein m is 1-3, n is 0-3, p is 0- 3, and the sum of m + n + p corresponds to the oxidation state of M.
• the metallocene is represented by the stoichiometric Formulas 3 or 4:
• each C 5 R 3 g is a substituted or unsubstituted cyclopentadienyl, wherein each R 3 may be the same or different and is hydrogen, alkyl, alkenyl, alkaryl or aralkyl having from 1 to 20 carbon atoms or at least 2 carbon atoms joined together to form a part of a C 4 to C 6 ring; wherein R 4 is either 1) an alkylene radical containing from 1 to 4 carbon atoms, or 2) a dialkyl germanium or silicon or an alkyl phosphoric or amine radical, and R 4 is substituting on and bridging two C 5 R 3 g rings or bridging one C 5 R 3 g ring back to M, wherein each Q can be the same or different and is an alkyl, alkenyl, aryl, alkaryl, or arylalkyl radical having from 1 to 20 carbon atoms or halogen, and Q' is an alkylidene radical having from 1 to 20 carbon atoms;
• the catalyst instead of being a metallocene, is a complex of stoichiometric Formula 5, 6, 7 or 8 having a bidentate ligand:
• the transition metal M is selected from the group consisting of Ti, Zr, Sc, V, Cr, a rare earth metal, Fe, Co, Ni, or Pd;
• X and X 1 are independently selected from the group consisting of halogen, hydrocarbyl group, and hydrocarboxyl group having 1 to 20 carbon atoms;
• n and p are integers whose sum is the valency of M minus 2 (the number of bonds between M and the bidentate ligand),
• R 5 and R 8 are each independently hydrocarbyl or substituted hydrocarbyl, provided that the carbon atom bound to the imino nitrogen atom has at least two carbon atoms bound to it;
• R 6 and R 7 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or R 6 and R 7 taken together are hydrocarbylene or substituted hydrocarbylene to form a carbocyclic ring;
• R 9 and R 2 are each independently hydrogen, hydrocarbyl or substituted hydrocarbyl;
• M is Pd, a diene is not present, and when a complex of Formula 7 is employed, M is not Pd.
• M is preferably Co, Fe, Ni or Pd; and is more preferably Ni or Pd. In Formula 7, n is 2 or 3.
• the aforesaid bulky ligand transition metal complex is a complex of stoichiometric Formula 9:
• transition metal M selected from Co, Fe, Ru and Mn
• G comprises one or more organic moieties to which the three nitrogen atoms N ⁇ N 2 and N 3 are collectively or separately bonded
• X and X 1 are independently selected from the group consisting of halogen, hydrocarbyl group and hydrocarboxyl group having 1 to 20 carbon atoms
• n and p are integers whose sum is the valency of M minus 3 (the number of bonds between M and the tridentate ligand); and wherein when M is Co, the sum of the integers n and p is 1 , 2, or 3, when M is Ru, the sum of n and p is 2, 3, or 4, when M is Fe, the sum of n and p is 2 or 3, and when M is Mn, the sum of n and p is 1 , 2, 3 or 4.
• M is Fe[ll], Fe[lll], Co[l], Co[ll], Co[lll], Ru [II], Ru[IV], Mn[l], Mn[ll], Mn[lll] or Mn[IV];
• X and X 1 are independently selected from the group consisting of halogen, hydrocarbyl group and hydrocarboxyl group having 1 to 20 carbon atoms; wherein n and p are integers whose sum is the valency of M; wherein R 24 , R 25 , R 26 , R 27 , and R 29 are independently selected from hydrogen, halogen, hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl, and wherein
• R 28 and R 30 are independently selected from hydrogen, halogen, hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl; and when any two or more of R 24 - R 30 are hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl, said two or more can be linked to form one or more cyclic substituents, or
• R 28 is represented by the stoichiometric Formula 11
• R 30 is represented by the stoichiometric Formula 12 as follows:
• R 31 to R 40 are independently selected from hydrogen, halogen, hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl; and wherein when any two or more of R 24 to R 27 , R 29 and R 31 to R 40 are hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl, said two or more can be linked to form one or more cyclic substituents; with the proviso that at least one of R 31 , R 32 , R 33 and R 34 is hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl when neither of the ring systems of Formulas 11 or 12 forms part of a polyaromatic fused-ring system, or
• R 28 is a group having the formula - NR 41 R 42 and R 30 is a group having the formula -NR 43 R 44 , wherein R 41 to R 44 are independently selected from hydrogen, halogen, hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl; and wherein when any two or more of R 24 to R 27 , R 29 and R 41 to R 44 are hydrocarbyl, substituted hydrocarbyl, heterohydrocarbyl or substituted heterohydrocarbyl, such two or more can be linked to form one or more cyclic substituents.
• the catalyst system employed in step (a) of the method of this invention also contains an activating quantity of an activator selected from organoaluminum compounds and hydrocarbylboron compounds.
• Suitable organoaluminum compounds include compounds of the formula AIR 50 3 , where each R 50 is independently C r C 12 alkyl or halo.
• TMA trimethylaluminium
• TEA triethylaluminium
• TIBA tri- isobutylaluminium
• tri-n-octylaluminium methylaluminiumdichloride, ethylaluminium dichloride, dimethylaluminium chloride, diethylaluminium chloride, ethylaluminums ⁇ squichloride, methyialuminumsesquichloride, and alumoxanes.
• Alumoxanes are well known in the art as typically the oligomeric compounds which can be prepared by the controlled addition of water to an alkylaluminium compound, for example trimethylaluminium.
• Such compounds can be linear, cyclic or mixtures thereof.
• Commercially available alumoxanes are generally believed to be mixtures of linear and cyclic compounds.
• the cyclic alumoxanes can be represented by the formula [R 51 AIO] s and the linear alumoxanes by the formula R 52 (R 53 AIO) s wherein s is a number from about 2 to 50, and wherein R 51 , R 52 , and R 53 represent hydrocarbyl groups, preferably C, to C 6 alkyl groups, for example methyl, ethyl or butyl groups.
• Alkylalumoxanes such as methylalumoxane (MAO) are preferred.
• alkylalumoxanes and trialkylaluminium compounds are particularly preferred, such as MAO with TMA or TIBA.
• alkylalumoxane as used in this specification includes alkylalumoxanes available commercially which may contain a proportion, typically about 10 weight percent, but optionally up to 50 weight percent, of the corresponding trialkylaluminium, for instance, commercial MAO usually contains approximately 10 weight percent trimethylaluminium (TMA), while commercial MMAO contains both TMA and TIBA.
• TMA trimethylaluminium
• alkylalumoxane quoted herein include such trialkylaluminium impurities, and accordingly quantities of trialkylaluminium compounds quoted herein are considered to comprise compounds of the formula AIR 3 additional to any AIR 3 compound incorporated within the alkylalumoxane when present.
• hydrocarbylboron compounds examples include boroxines, trimethylboron, triethylboron, dimethylphenylammoniumtetra(phenyl)borate, trityltetra(phenyl)borate, triphenylboron, dimethylphenylammonium, tetra(pentafluorophenyl)borate, sodium tetrakis[(bis-3,5-trifluoromethyl)phenyl]borate, trityltetra(pentafluorophenyl)borate and tris(pentafluorophenyl) boron.
• the quantity of activating compound selected from organoaluminium compounds and hydrocarbylboron compounds to be employed is easily determined by simple testing, for example, by the preparation of small test samples which can be used to polymerise small quantities of the monomer(s) and thus to determine the activity of the produced catalyst. It is generally found that the quantity employed is sufficient to provide 0.1 to 20,000 atoms, preferably 1 to 2000 atoms, of aluminum or boron per atom of the transition metal in the compound of Formula 1. Generally, from about 1 mole to about 5000 moles, preferably to about 150 moles of activator are employed per mole of transition metal complex.
• the catalyst when the catalyst system employed in step (a) of the method of this invention comprises a complex of Formulas 5-12, the catalyst preferably comprises a neutral Lewis Base in addition to the bulky ligand transition metal complex and the activator.
• Neutral Lewis bases are well known in the art of Ziegler-Natta catalyst polymerisation technology.
• classes of neutral Lewis bases suitably employed in the present invention are unsaturated hydrocarbons, for example, alkenes (other than 1- olefins) or alkynes, primary, secondary and tertiary amines, amides, phosphoramides, phosphines, phosphites, ethers, thioethers, nitriles, carbonyl compounds, for example, esters, ketones, aldehydes, carbon monoxide and carbon dioxide, sulphoxides, sulphones and boroxines.
• unsaturated hydrocarbons for example, alkenes (other than 1- olefins) or alkynes, primary, secondary and tertiary amines, amides, phosphoramides, phosphines, phosphites, ethers, thioethers, nitriles, carbonyl compounds, for example, esters, ketones, aldehydes, carbon monoxide and carbon dioxide, sulphoxid
• 1-olefins are capable of acting as neutral Lewis bases, for the purposes of the present invention they are regarded as monomer or comonomer 1-olefins and not as neutral Lewis bases per se.
• alkenes which are internal olefins, for example, 2-butene and cyclohexene are regarded as neutral Lewis bases in the present invention.
• Preferred Lewis bases are tertiary amines and aromatic esters, for example, dimethylaniline, diethylaniline, tributylamine, ethylbenzoate and benzylbenzoate.
• the transition metal complex (first component), activator (second component), and neutral Lewis base (third component) of the catalyst system can be brought together simultaneously or in any desired order.
• the aforesaid second and third are compounds which interact together strongly, for example, form a stable compound together, it is preferred to bring together either the aforesaid first and second components or aforesaid first and third components in an initial step before introducing the final defined component.
• the first and third components are contacted together before the second component is introduced.
• the quantities of first and second components employed in the preparation of this catalyst system are suitably as described above in relation to the catalysts of the present invention.
• the quantity of the neutral Lewis Base (component 3) is preferably such as to provide a ratio of the neutral Lewis Base to the first component of 100:1 to 1 :1000, most preferably in the range 10:1 to 1 :20.
• All three components of the catalyst system can be brought together, for example, as the neat materials, as a suspension or solution of the materials in a suitable diluent or solvent (for example a liquid hydrocarbon), or, if at least one of the components is volatile, by utilising the vapour of that component.
• the components can be brought together at any desired temperature. Mixing the components together at room temperature is generally satisfactory. Heating to higher temperatures, for example, up to 120°C, can be carried out if desired, for example, to achieve better mixing of the components.
• the catalyst it is preferred to carry out the bringing together of the three components in an inert atmosphere (for example, dry nitrogen) or in vacuo.
• an inert atmosphere for example, dry nitrogen
• this can be achieved, for example, by preforming the catalyst system comprising the three components and impregnating the support material preferably with a solution thereof, or by introducing to the support material one or more of the components simultaneously or sequentially.
• the support material itself can have the properties of a neutral Lewis base and can be employed as, or in place of, the aforesaid third component.
• An example of a support material having neutral Lewis base properties is poly(aminostyrene) or a copolymer of styrene and aminostyrene (ie vinylaniline).
• the catalysts of the present invention can, if desired, comprise more than one of the defined transition metal compounds.
• the catalyst may comprise, for example, a mixture of 2,6-diacetylpyridinebis(2,6-diisopropylanil)FeCI 2 complex and 2,6- diacetylpyridinebis(2,4,6-trimethylanil)FeCI 2 complex, or a mixture of 2,6- diacetylpyridine(2,6-diisopropylanil)CoCI 2 and 2,6-diacetylpyridinebis(2,4,6- trimethylanil)FeCI 2 .
• the catalysts of the present invention can also include one or more other types of transition metal compounds or catalysts, for example, transition metal compounds of the type used in conventional Ziegler-Natta catalyst systems, metallocene-based catalysts, or heat activated supported chromium oxide catalysts (eg Phillips-type catalyst).
• the catalyst employed in the process step (a) of the present invention can be unsupported or supported (absorbed or adsorbed or chemically bound) on a convenient conventional' support material.
• Suitable solid particle supports are typically comprised of polymeric or refractory oxide materials, each being preferably porous, such as for example, talc, inorganic oxides, inorganic chlorides, for example magnesium chloride, and resinous support materials such as polystyrene, polyolefin, or other polymeric compounds or any other organic support material and the like that has an average particle size preferably greater than 10 ⁇ m.
• the preferred support materials are inorganic oxide materials, which include those from the Periodic Table of Elements of Groups 2, 3, 4, 5, 13 or 14 metals or metalloid oxides.
• the catalyst support materials include silica, alumina, silica-alumina, and mixtures thereof.
• Other inorganic oxides that may be employed either alone or in combination with the silica, alumina or silica-alumina are magnesia, titania, zirconia, and the like.
• the support material 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 10 to about 500 ⁇ m. More preferably, the surface area is in the range of from about 50 to about 500 m 2 /g, the pore volume is in the range of from about 0.5 to about 3.5 cc/g, and the average particle size is in the range of from about 20 to about 200 ⁇ m. Most preferably, the surface area range is from about 100 to about 400 m 2 /g; the pore volume is from about 0.8 to about 3.0 cc/g, and the average particle size is from about 30 to about 100 ⁇ m.
• the pore size of the carrier of the invention typically has pore size in the range of from 10 to about 1000A, preferably 50 to about 500 A, and more preferably 75 to about 350 A.
• the bulky ligand transition metal compound is deposited on the support generally at a loading level of 100 to 10 micromoles of transition metal compound to gram of solid support; more preferably from 80 to 20 micromoles of transition metal compound to gram of solid support; and most preferably from 60 to 40 micromoles of transition metal compound to gram of solid support.
• the bulky ligand transition metal compound can be deposited on the support at any level up to the pore volume of the support, loading levels of less than 100 micromoles of transition metal compound to gram of solid support are preferred, with less than 80 micromoles of transition metal compound to gram of solid support being more preferred, and less than 60 micromoles of transition metal compound to gram of solid support being most preferred.
• Impregnation of the support material can be carried out by conventional techniques, for example, by forming a solution or suspension of the catalyst components in a suitable diluent or solvent, or slurrying the support material therewith. The support material thus impregnated with catalyst can then be separated from the diluent for example, by filtration or evaporation techniques.
• the catalysts can be formed in situ in the presence of the support material, or the support material can be pre-impregnated or premixed, simultaneously or sequentially, with one or more of the catalyst components.
• Formation of the supported catalyst can be achieved, for example, by treating the transition metal compounds of the present invention with alumoxane in a suitable inert diluent, for example, a volatile hydrocarbon, slurrying a particulate support material with the product and evaporating the volatile diluent.
• the produced supported catalyst is preferably in the form of a free-flowing powder.
• the quantity of support material employed can vary widely, for example from 100,000 to 1 grams per gram of metal present in the transition metal compound.
• the polymerization conditions employed in step (a) of the method of this invention can be, for example, either solution phase, slurry phase, or gas phase and either batch, continuous or semi-continuous, with polymerization temperatures ranging from -100°C to +300°C.
• the catalyst is generally fed to the polymerization zone in the form of a particulate solid.
• This solid can be, for example, an undiluted solid catalyst system formed from the bulky ligand transition metal complex employed in the method of the present invention and an activator, or can be the solid complex alone. In the latter situation, the activator can be fed to the polymerization zone, for example as a solution, separately from or together with the solid complex.
• the solid particles of catalyst, or supported catalyst are fed to a polymerisation zone either as dry powder or as a slurry in the polymerisation diluent.
• the particles are fed to a polymerisation zone as a suspension in the polymerisation diluent.
• the polymerisation zone can be, for example, an autoclave or similar reaction vessel, or a continuous loop reactor, e.g. of the type well-known' in the manufacture of polyethylene by the Phillips Process.
• Methods for operating gas phase polymerisation processes are well known in the art. Such methods generally involve agitating (e.g. by stirring, vibrating or fluidising) a bed of catalyst, or a bed of the target polymer (i.e.
• polymer having the same or similar physical properties to that which it is desired to make in the polymerisation process) containing a catalyst, and feeding thereto a stream of monomer at least partially in the gaseous phase, under conditions such that at least part of the monomer polymerises in contact with the catalyst bed.
• the bed is generally cooled by addition of cool gas (e.g. recycled gaseous monomer) and/or volatile liquid (e.g. a volatile inert hydrocarbon, or gaseous monomer which has been condensed to form a liquid).
• cool gas e.g. recycled gaseous monomer
• volatile liquid e.g. a volatile inert hydrocarbon, or gaseous monomer which has been condensed to form a liquid.
• the polymer produced in, and isolated from, gas phase processes forms directly a solid in the polymerisation zone and is free from liquid, or substantially free from liquid.
• Step (a) of the present invention can be operated under batch, semi-batch, or so-called “continuous” conditions by methods that are well known in the art.
• the polymerisation process of the step (a) of the method of the present invention is preferably carried out at a temperature above 0°C, most preferably above 15°C. Adjustment of the polymerisation within these defined temperature ranges can provide a useful means of controlling the average molecular weight of the produced polymer.
• Monomers that are suitable for use as the olefin that undergoes reaction in step (a) of the process of the present invention are alpha-olefins which have (1) at least one hydrogen on the 2-carbon atom, (2) at least two hydrogens on the 3-carbon atoms, and (3) at least one hydrogen on the 4-carbon (if at least 4 carbon atoms are present in the olefin).
• R 60 is an alkyl, preferably containing from 1 to 19 carbon atoms, and more preferably from 2 to 13 atoms. Therefore, useful alpha-olefins include propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1- hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene and mixtures thereof.
• Step (a) of the process of the present invention is controlled to make polymer having a number average molecular weight of not greater than 15,000 and typically from 300 to 15,000, and preferably from 400 to 8,000.
• the number average molecular weight for such polymers can be determined by any convenient known technique.
• One convenient method for such determination is by size exclusion chromatography (also known as gel permeation chromatography, GPC) which additionally provides molecular weight distribution information (see W. W. Yau, J. J. Kirkland and D. D. Bly, "Modern Size Exclusion Liquid Chromatography", John Wiley and Sons, New York, 1979).
• the molecular weight distribution (Mw/Mn) of the polymers or copolymers produced in step (a) is typically less than 5, preferably less than 4, more preferably less than 3, e.g., between 1.5 and 2.5.
• the polymers produced in step (a) of this invention are further characterized in that up to about 50% or more of the polymer chains possess terminal ethylenylidene-type unsaturation.
• the polymer products of step (a) of this inventive process comprise chains which can be saturated by hydrogen, but preferably contain polymer chains wherein at least 50, preferably at least 60, and more preferably at least 75 percent (e.g. 75-98%), of which exhibit terminal ethenylidene (vinylidene) unsaturation.
• the percentage of polymer chains exhibiting terminal ethenylidene unsaturation may be determined by Fourier Transform Infrared (FTIR) spectroscopic analysis, titration, proton (H)NMR, or C 13 NMR.
• FTIR Fourier Transform Infrared
• step (a) is conducted under solution phase conditions using a catalyst system comprising a catalyst of Formula 2, 3 or 4, in which M is a Group IVb transition metal, typically titanium, zirconium or hafnium, and aluminoxane as an activator with the molar ratio of aluminoxane to metallocene of 150 or greater, and C 3 -C 20 alpha-olefins in a feedstock containing more than 1 weight percent of at least one volatile hydrocarbon liquid but consisting essentially of the C 3 - C 20 alpha-olefins, are polymerized to form an essentially terminally-unsaturated, viscous, essentially-1-olefin-containing poly(1 -olefin) or copoly(1 -olefin), having a terminal vinylidene content of more than 50%.
• M is a Group IVb transition metal, typically titanium, zirconium or hafnium
• aluminoxane as an activator with the molar
• the terminally unsaturated, viscous polymer product of this invention is essentially a poly( 1-olefin) or copoly( 1-olefin).
• the polymer chains of the viscous polymers produced in step (a) of the method of this invention are essentially terminally-unsaturated.
• essentially terminally- unsaturated is meant that preferably more than about 90% of the polymer chains contain unsaturation, more preferably more than about 95% of the polymer chains in the product polymer contain terminal unsaturation.
• the polymers produced in step (a) of this invention are further characterized, following removal of lights ( ⁇ C26), by having a viscosity between 5 and 200 cSt, a viscosity index between 110 and 230, a pour pt less than - 20°C, and a Noack volatility at 250°C between 1% and 20%.
• the polymers produced in step (a) of this invention are further characterized, following removal of lights ( ⁇ C26), by having a viscosity between 5 and 230 cSt, a viscosity index between 110 and 200, a pour pt less than - 20°C, and Noack volatility at 250°C between 1 % and 20%.
• the products produced in step (a) are mixtures whose components and their relative amounts depend upon the particular alpha-olefin reactant, the catalyst and reaction conditions employed.
• the products are unsaturated and have viscosities ranging from about 2 to about 100 cSt at 100°C.
• At least a portion of the product mixture generally has the desired properties, for example, viscosity, for a particular application.
• the components in such portion are usually hydrogenated to improve their oxidation resistance and are known for their superior properties of long-life, low volatility, low pour points and high viscosity indices, which make them a premier basestock for state-of-the-art lubricants and hydraulic fluids.
• step (a) is often performed under conditions that are necessary to produce a product mixture that contains an undesired excess or inadequate amount of one product in order to obtain the desired amount of another product.
• step (a) fractionating the product mixture produced in step (a) in order to separate and recover one or more fraction, containing the components having the desired properties and separating one or more other fraction of the product mixture for additional processing in step (b) of the method of this invention.
• step (b) the entire product from step (a) can be oligomerized in step (b).
• step (b) permits the olefin feed to step (a) to be converted with greater efficiency to desired amounts of products having desired properties.
• the method of the present invention permits improved control of the makeup of the feed and permits a wide range of customer specific oligomer oil products to be produced.
• Any suitable oligomerization catalyst known in the art, especially an acidic oligomerization catalyst system, and especially Friedel-Crafts type catalysts such as acid halides (Lewis Acid) or proton acid (Bronsted Acid) catalysts can be employed as the oligomerization catalyst of step (b).
• oligomerization catalysts include but are not limited to BF 3 , BCI 3 , BBr 3 , sulfuric acid, anhydrous HF, phosphoric acid, polyphosphoric acid, perchloric acid, fluorosulfuric acid, aromatic sulfuric acids, and the like.
• Such catalysts can be used in combination and with promoters such as water, alcohols, hydrogen halide, alkyl halides and the like.
• a preferred catalyst system for the oligomerization process of step (b) is the BF 3 - promoter catalyst system.
• Suitable promoters are polar compounds ' and preferably alcohols containing about 1 to 10 carbon atoms such as methanol, ethanol, isopropanol, n-propanol, n-butanol, isobutanol, n-hexanol, n-octanol and the like.
• Other suitable promoters include, for example, water, phosphoric acid, fatty acids (e.g. valeric acid) aldehydes, acid anhydrides, ketones, organic esters, ethers, polyhydric alcohols, phenols, ether alcohols and the like.
• the ethers, esters, acid anhydrides, ketones and aldehydes provide good promotion properties when combined with other promoters which have an active proton e.g. water or alcohols.
• Amounts of promoter are used which are effective to provide good conversions in a reasonable time. Generally, amounts of 0.01 weight percent or greater, based on the total amounts of olefin reactants, can be used. Amounts greater than 1.0 weight percent can be used but are not usually necessary. Preferred amounts range from about 0.025 to 0.5 weight percent of the total amount of olefin reactants. Amounts of BF 3 are used to provide molar ratios of BF 3 to promoter of from about 0.1 to 10:1 and preferably greater than about 1 :1. For example, amounts of BF 3 of from about 0.1 to 3.0 weight percent of the total amount of olefin reactants are employed.
• the amount of catalyst used can be kept to a minimum by bubbling BF 3 into an agitated mixture of the olefin reactant only until an "observable" condition is satisfied, i.e. a 2°-4°C increase in temperature. Because the vinylidene olefins are more reactive than vinyl olefin, less BF 3 catalyst is needed compared to the vinyl olefin oligomerization process normally used to produce PAO's.
• step (a) The high degree of vinylidine type unsaturation of the product of step (a) when catalysts of Formula 2, 3, or 4 are used makes the product very reactive in the oligomerization of step (b).
• step (b) since either the entire amount of product of step (a) or one or more preselected fractions of it can be oligomerized in step (b), it is possible in the method of this invention to tailor the feedstock to step (b) in order to produce the desired relative amounts of each viscosity product desired without producing an excess of one product in order to obtain the desired amount of another product which is desired.
• a further embodiment of the method of this invention is to co-oligomerize in step (b) a pre-selected fraction of the product of step (a) with at least one vinyl olefin containing 4 to 20 carbon atoms.
• This allows ' for conversion of a Traction of the product of step (a) which may not be useful, for example, the dimer fraction, to a higher fraction, for example, a trimer fraction, which is useful.
• the addition of a different vinyl olefin than used in step (a) to the feed of step (b) permits further control of the make-up of the feed to step (b), and an even wider range of customer specific oligomer oils to be produced.
• oligomer fraction which could not easily be made from other means, for example, co-oligomerizing the C 20 polymer from step (a) with C 12 vinyl olefin in step (b) to form primarily a C 32 product.
• the identity of the vinyl olefin employed and the relative amounts of vinyl olefin and aforesaid fraction of the product mixture of step (a) in step (b) can be varied to control the amount of products formed in step (b).
• Suitable vinyl olefins for use as additional compounds to be added to the feed to step (b) in the process contain from 4 to about 30 carbon atoms, and, preferably, about 6 to 20 carbon atoms, including mixtures thereof.
• Non-limiting examples include 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene and the like.
• Pure vinyl olefins or a mixture of vinyl olefins and vinylidene and/or internal olefins can be used.
• the feed contains at least about 85 weight percent vinyl olefin.
• step (b) can be run so that only a fraction of the vinyl olefin reacts with the preselected polymer fraction from step (a).
• step (b) By varying the choice of the fraction of the product of step (a) that is employed in the feed to step (b) and of the vinyl olefin added in step (b), customer-specific oligomer oil products can be produced.
• the viscosity of such a product can be varied by changing the amount and type of vinyl olefin added to the reaction mixture for the second step.
• a range of molar ratios of aforesaid pre-selected fraction of the product of step (a) to the vinyl olefin added can be varied, but usually at least a molar equivalent amount of vinyl olefin to aforesaid pre-selected fraction of the product of step (a) is used in order to consume the aforesaid pre-selected fraction of the product of step (a).
• the product oils have viscosities of from about 1 to 20 cSt at 100°C.
• mole ratios of from about 10:1 to 1 :1.5 and most typically about 1.3:1 of the added vinyl olefin to the aforesaid pre-selected fraction of the product of step (a) are used for the feed to step (b).
• the vinyl olefin is typically added at a time when at least "about 30 percent by weight of the aforesaid pre-s ⁇ lected fraction of the product of step (a) has been oligomerized in step (b).
• Step (b) can be carried out at atmospheric pressure. Moderately elevated pressures, e.g. to 50 pounds per square inch, can be used and may be desirable to minimize reaction time but are not necessary because of the high reactivity of the vinylidene olefin.
• Reaction times and temperatures in step (b) are chosen to efficiently obtain good conversions to the desired product. Generally, temperatures of from about 0° to 70°C are used with total reaction times of from about 1/2 to 5 hours.
• the products from step (b) of the method of the present invention do have the pre-selected desired properties, especially viscosity.
• the products of step (b) are characterized, following removal of unreacted monomer and dimer, by having a viscosity between 3 and 100 cSt, a viscosity index between 110 and 180, a pour pt less than - 30°C, and a Noack volatility at 250°C between 2% and 25%.
• the first three examples illustrate the polymerizations in step (a) of 1-decene catalyzed by zirconocene dichloride with a methylaluminoxane activator at three different temperatures.
• Example 4 differs in that instead zirconocene dimethyl with a borate activator is employed in step (a).
• EXAMPLE 1 A 2-liter Parr reactor under nitrogen was charged with 1096 g of dry 1-decene and was taken to 65°C with stirring.
• MAO methylaluminoxane
• the catalyst solution was injected to the Parr reactor using an injection vessel.
• the reaction was stirred at temperature (65°C) for 3 hours and then quenched by pouring the content into a quench vessel containing 200 mL of 2N NaOH and the organic layer was washed.
• EXAMPLE 4 A 2-liter Parr reactor under nitrogen was charged with 882 g of dry 1-decene and was heated to 100° C with stirring.
• the catalyst was prepared by pre-mixing for 10 minutes a solution of 3.5 mg of bis(cyclopentadienyl)zirconium dimethyl in 20 mL of toluene with 11.1 mg of a solution of N,N-dimethylanalinium tetra(pefluorophenyl)borate in 50 mL toluene and 0.20 mL of triisobutylaluminum.
• the catalyst solution was injected to the Parr reactor using an injection vessel.
• the reaction was stirred at temperature (100°C) for 3 hours and then quenched by pouring the content into a quench vessel containing 200 mL of 2N NaOH and the organic layer was washed. The organic layer was subsequently washed with distilled water (2 x 200 mL) and dried over MgSO 4 . Removal of unreacted decene under reduced pressure resulted in isolation of 197.2 g of a clear fluid. Further distillation of this fluid under reduced pressure resulted in isolation of 49.2 g (24.9%) of the dimeric C20 fluid having about 60% vinylidene by NMR.
• the bottom fraction was hydrogenated under a set of standard hydrogenation conditions (at 170°C, 400 psi hydrogen, using Ni on Kieselguhr catalyst) to produce a high viscosity index (VI) synthetic basestock having the following properties:
• Example 4 shows a vinylidene olefin content of about 60%:
• Example 5 the dimer (C20) fraction from the product of step (a) in
• Examples 1-3 is reacted with 1-decene in step (b) to form a more useful product, primarily trimer (C30) and tetramer (C40).
• Example 6 demonstrates that the product of step (b) is unaffected if the dimer fraction of the product of step (a) is made using a borate activator or an MAO activator.
• a 1 -gallon Parr reactor was charged with 643.0 g of the C20 dimeric fluid isolated from Examples 1-3, 357.0 g 1-decene, 2.0 g 1-butanol and was taken to
• Kieselguhr catalyst to produce a high viscosity index (VI) synthetic basestock having the following properties:
• a 1 -gallon Parr reactor was charged with 536.0 g of the C20 dimeric fluid isolated from runs identical to Example 4 (metallocene/borate catalyst system), 356.0 g 1-decene, 1.0 g 1-propanol and was taken to 35°C with stirring. Boron trifluoride was introduced and it was adjusted slowly to a steady state pressure of 20 psi. The reaction mixture was stirred for 2 hours. Product was isolated in a manner identical to
• Example 5 resulting in isolation of 700.9 of a clear fluid prior to hydrogenation. Gas chromatography analysis of this product mixture was virtually identical to the product isolated when the C20 dimeric fluid of this experiment was replaced with C20 fluid of
• Example 1-3 This indicates fluids having the same physical properties are obtained for dimeric products derived from metallocene/MAO catalyst system (Examples 1-3) and metallocene/borate catalyst system (Example 4).
• Example 7 illustrates the reaction of the dimer (C20) fraction of the product of step (a) with 1-dodecene to make a product of step (b), primarily C32, which could not easily be made in a high yield by any one-step process.
• Example 9 differs from
• Example 7 in that tetradecene is used in step (b), again to make a product, primarily
• Example 8 illustrates the polymerization of 1-decene in step (a) followed by the removal of unreacted 1-decene, and the subsequent reaction of all of the remaining product of step (a) with 1-dodecene in step (b).
• the dimer portion of the product of step (a) can be converted to more useful higher oligomers in step (b) with or without first removing it from the rest of the product of step (a).
• EXAMPLE 7 A 1 -gallon Parr reactor was charged with 651.2 g of the C20 dimeric fluid isolated from Examples 1-3, 400.1 g 1-dodecene, 1.0 g 1-propanol and was taken to 45°C with stirring. Boron trifluoride was introduced and it was adjusted slowly to a steady state pressure of 20 psi. The reaction mixture was stirred for 2 hours. The reaction mixture was quenched with 500 g of 8% NaOH and washed with distilled water.
• a 2-liter Parr reactor under nitrogen was charged with 1094 g of dry 1- decene and was taken to 100°C with stirring.
• MAO methylaluminoxane
• reaction was stirred at temperature (100°C) for 3 hours and then quenched by pouring the content into a quench vessel containing 200 mL of 2N NaOH and the organic layer was washed. The organic layer was subsequently washed with distilled water (2 x 200 mL) and dried over MgSO 4 . Removal of unreacted decene under reduced pressure resulted in isolation of 908.6 g of a clear fluid.
• a 1 -gallon Parr reactor was charged with 710.0 g of above isolated fluid, 357.0 g 1-dodecene, 3.0 g 1-butanol and was taken to 50°C with stirring.
• EXAMPLE 9 A 1 -gallon Parr reactor was charged with 650.0 g of the C20 dimeric fluid isolated from Examples 1-3, 350.0 g 1-tetradecene, 1.0 g 1-propanol and was taken to 40°C with stirring. Boron trifluoride was introduced and it was adjusted slowly to a steady state pressure of 20 psi. The reaction mixture was stirred for 2 hours. The reaction mixture was quenched with 500 g of 8% NaOH and washed with distilled water.
• the reactor is pressurized with ethylene to 100 kPa and the polymerization was continued for 10 hours.
• the reaction is depressurized from ethylene by venting and the reaction is quenched after 10 hours in a manner similar to Example 1 and the product is isolated. It is possible to produce product varying in viscosity from 2 to greater 500 cSt by changing the catalyst, polymerization temperature, ethylene pressure or a combination thereof.
• the reactor is pressurized with ethylene to 100 kPa and the polymerization was continued for 10 hours.
• the reaction is depressurized from ethylene by venting and the reaction is quenched after 10 hours in a manner similar to Example 1 and the product is isolated. It is possible to produce product varying in viscosity from 2 to greater 500 cSt by changing the catalyst, polymerization temperature, ethylene pressure or a combination thereof.
• the reaction is depressurized from ethylene by venting and the reaction is quenched after 10 hours in a manner similar to Example 1 and the product is isolated. It is possible to produce product varying in viscosity from 2 to greater 500 cSt by changing the catalyst, polymerization temperature, ethylene pressure or a combination thereof.

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