WO2007127416A2 - Fluorinated transition metal catalysts and formation thereof - Google Patents
Fluorinated transition metal catalysts and formation thereof Download PDFInfo
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- WO2007127416A2 WO2007127416A2 PCT/US2007/010318 US2007010318W WO2007127416A2 WO 2007127416 A2 WO2007127416 A2 WO 2007127416A2 US 2007010318 W US2007010318 W US 2007010318W WO 2007127416 A2 WO2007127416 A2 WO 2007127416A2
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- 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
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- 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
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- 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
- C08F10/04—Monomers containing three or four carbon atoms
- C08F10/06—Propene
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- 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
- B01J2231/00—Catalytic reactions performed with catalysts classified in B01J31/00
- B01J2231/10—Polymerisation reactions involving at least dual use catalysts, e.g. for both oligomerisation and polymerisation
- B01J2231/12—Olefin polymerisation or copolymerisation
- B01J2231/122—Cationic (co)polymerisation, e.g. single-site or Ziegler-Natta type
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- 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
- B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
- B01J2531/40—Complexes comprising metals of Group IV (IVA or IVB) as the central metal
- B01J2531/46—Titanium
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- 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
- B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
- B01J2531/40—Complexes comprising metals of Group IV (IVA or IVB) as the central metal
- B01J2531/48—Zirconium
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- 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
- B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
- B01J2531/40—Complexes comprising metals of Group IV (IVA or IVB) as the central metal
- B01J2531/49—Hafnium
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
- C08F110/04—Monomers containing three or four carbon atoms
- C08F110/06—Propene
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- 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
- C08F2410/00—Features related to the catalyst preparation, the catalyst use or to the deactivation of the catalyst
- C08F2410/07—Catalyst support treated by an anion, e.g. Cl-, F-, SO42-
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F4/00—Polymerisation catalysts
- C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
- C08F4/62—Refractory metals or compounds thereof
- C08F4/64—Titanium, zirconium, hafnium or compounds thereof
- C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
- C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
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- 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
- C08F4/65927—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 bridged
Definitions
- Embodiments of the present invention generally relate to supported catalyst compositions and methods of forming the same.
- olefin polymers include contacting olefin monomers with transition metal catalyst systems, such as metallocene catalyst systems to form polyolefins. While it is widely recognized that the transition metal catalyst systems are capable of producing polymers having desirable properties, the transition metal catalysts generally do not experience commercially viable activities.
- transition metal catalyst systems such as metallocene catalyst systems
- Embodiments of the present invention include methods of forming supported catalyst systems and the catalyst systems formed therefrom.
- the methods generally include providing an inorganic support composition, wherein the inorganic support composition comprises aluminum, fluorine and silica and contacting the inorganic support composition with a transition metal compound to form a supported catalyst system, wherein the transition metal compound is represented by the formula [L] m M[A] n ; wherein L is a bulky ligand, A is a leaving group, M is a transition metal and m and n are such that a total ligand valency corresponds to the transition metal valency.
- the methods further include contacting the inorganic support composition, the transition metal compound, the supported catalyst system or combinations thereof with at least one compound represented by the formula XR n , wherein X is selected from Group 12 to 13 metals, lanthanide series metals or combinations thereof and each R is independently selected from alkyls, alkoxys, aryls, aryloxys, halogens, hydrides, Group 1 or 2 metals, organic nitrogen compounds, organic phosphorous compounds and combinations thereof and n is from.2 to 5.
- X is selected from Group 12 to 13 metals, lanthanide series metals or combinations thereof and each R is independently selected from alkyls, alkoxys, aryls, aryloxys, halogens, hydrides, Group 1 or 2 metals, organic nitrogen compounds, organic phosphorous compounds and combinations thereof and n is from.2 to 5.
- the method includes contacting the inorganic support composition, the transition metal compound, the supported catalyst system or combinations thereof with a plurality of compounds, wherein the plurality of compounds include a first compound including an organo aluminum compound and a second compound including boron.
- Embodiments further include polymerization processes. Such processes generally include contacting the supported catalyst system with an olefin monomer to form a poly olefin.
- room temperature may include a temperature of from about 20 0 C to about 28°C (68 0 F to 82°F), while in other environments, room temperature may include a temperature of from about
- room temperature measurements generally do . not include close monitoring of the temperature of the process and therefore such a recitation does not intend to bind the embodiments described herein to any predetermined temperature range.
- fluorinated support refers to a support that includes fluorine or fluoride molecules (e.g., incorporated therein or on the support surface.)
- the term "activity" refers to the weight of product produced per weight of the catalyst used in a process per hour of reaction at a standard set of conditions ⁇ e.g., grams product/gram catalyst/hr).
- substituted refers to an atom, radical or group replacing hydrogen in a chemical compound.
- the term "tacticity” refers to the arrangement of pendant groups in a polymer.
- a polymer is “atactic” when its pendant groups are arranged in a random fashion on both sides of the chain of the polymer.
- a polymer is “isotactic” when all of its pendant groups are arranged on the same side of the chain and “syndiotactic” when its pendant groups alternate on opposite sides of the chain.
- bonding sequence refers to an elements sequence, wherein each element is connected to another by sigma bonds, dative bonds, ionic bonds or combinations thereof.
- Embodiments of the invention generally include supported catalyst compositions.
- the catalyst compositions generally include a support composition and a transition metal compound, which are described in greater detail below. [0018] Such catalyst compositions generally are formed by contacting a support composition with a fluorinating agent to form a fluorinated support and contacting the fluorinated support with a transition metal compound to form a supported catalyst system.
- the catalyst systems may be formed in a number of ways and sequences.
- the support composition as used herein is an aluminum containing support material.
- the support material may include an inorganic support composition.
- the support material may include talc, inorganic oxides, clays and clay minerals, ion-exchanged layered compounds, diatomaceous earth compounds, zeolites or a resinous support material, such as a polyolefin, for example.
- Specific inorganic oxides include silica, alumina, magnesia, titania and zirconia, for example.
- the support composition is an aluminum containing silica support material.
- the support composition is formed of spherical particles.
- the aluminum containing silica support materials may have an average particle/pore size of from about 5 microns to 100 microns, or from about 15 microns to about 30 microns, or from about 10 microns to 100 microns or from about 10 microns to about 30 microns, a surface area of from 50 m 2 /g to 1,000 m 2 /g, or from about 80 m 2 /g to about 800 m 2 /g, or from 100 m 2 /g to 400 m 2 /g, or from about 200 m 2 /g to about 300 m 2 /g or from about 150 m 2 /g to about 300 m 2 /g and a pore volume of from about 0.1 cc/g to about 5 cc/g, or from about 0.5 cc/g to about 3.5 cc/g, or from about 0.5 cc/g to about 2.0 cc/g or from about 1.0 cc/g to about 1.5 cc/g, for
- the aluminum containing silica support materials may further have an effective number or reactive hydroxyl groups, e.g., a number that is sufficient for binding the fluorinating agent to the support material.
- the number of reactive hydroxyl groups may be in excess of the number needed to bind the fluorinating agent to the support material is minimized.
- the support material may include from about 0.1 mmol OHVg Si to about 5 mmol OHVg Si, or from about 0.25 mmol OHVg Si to about 4 mmol OH ' /g Si or from from about 0.5 inmol OHVg Si to about 3 mmol OHVg Si.
- the aluminum containing silica support materials are generally commercially available materials, such as PlO silica alumina that is commercially available from Fuji Sylisia Chemical LTD, for example (e.g., silica alumina having a surface area of 281 m 2 /g and a pore volume of 1.4 ml/g.)
- the aluminum containing silica support materials may further have an aluminum content of from about 0.5 wt.% to about 95 wt%, or from about 0.1 wt.% to about 50 wt.%, or from about 2 wt.% to about 25 wt.%, or from about 0.1 wt.% to about 20 wt.%, or from about 10 wt.% to about 20 wt.% or from about 13 wt.% to about 17 wt.%, for example.
- the aluminum containing silica support materials may further have a silica to aluminum molar ratio of from about 0.01: 1 to about 1000:1, or from about 0.1:1 to about 750:1 or from about 1:1 to about 500:1, for example.
- the aluminum containing silica support materials may be formed by contacting a silica support material with a first aluminum containing compound. Such contact may occur at a reaction temperature of from about room temperature to about 150 0 C.
- the formation may further include calcining at a calcining temperature of from about 150 0 C to about 600 0 C, or from about 200 0 C to about 600 0 C or from about 35°C to about 500 0 C, for example.
- the calcining occurs in the presence of an oxygen containing compound, for example.
- the support composition is prepared by a cogel method (e.g., a gel including both silica and alumina.)
- a cogel method refers to a preparation process including mixing a solution including the first aluminum containing compound into a gel of silica (e.g., Al 2 (SO 4 ) + H 2 SO 4 + Na 2 O-SiO 2 .)
- the first aluminum containing compound may include an organic aluminum containing compound.
- the organic aluminum containing compound may be represented by the formula AIR 3 , wherein each R is independently selected from alkyls, aryls and combinations thereof.
- the organic aluminum compound may include methyl alumoxane (MAO) or modified methyl alumoxane (MMAO), for example or, in a specific embodiment, triethyl aluminum (TEAl) or triisobutyl aluminum (TIBAl). for example.
- MAO methyl alumoxane
- MMAO modified methyl alumoxane
- TEAl triethyl aluminum
- TIBAl triisobutyl aluminum
- the support composition is fluorinated by methods known to one skilled in the art.
- the support composition may be contacted with a fluorinating agent to form the fluorinated support.
- the fluorination process may include contacting the support composition with the fluorinating agent at a first temperature of from about 100 0 C to about 200 0 C for a first time of from about 1 hour to about 10 hours or from about 1 hour to about 5 hours, for example and then raising the temperature to a second temperature of from about 250 0 C to about 550 0 C or from about 400 0 C to about 500 0 C for a second time of from about 1 hour to about 10 hours, for example.
- the "support composition" may be impregnated with aluminum prior to contact with the fluorinating agent, after contact with the fluorinating agent or simultaneously as contact with the fluorinating agent.
- the fluorinated support composition is formed by simultaneously forming SiO 2 and AI 2 O 3 and then contacting the resulting compound with the fluorinating agent.
- the fluorinated support composition is formed by contacting an aluminum containing silica support material with the fluorinating agent.
- the fluorinated support composition is formed by contacting a silica support material with the fluorinating agent and then contacting the fluorinated support with the first aluminum containing compound.
- the fluorinating agent generally includes any fluorinating agent which can form fluorinated supports.
- Suitable fluorinating agents include, but are not limited to, hydrofluoric acid (HF), ammonium fluoride (NH 4 F), ammonium bifluoride (NH 4 HF 2 ), ammonium fluoroborate (NH 4 BF 4 ), ammonium silicofluoride ((NH-O 2 SiFe), ammonium fluorophosphates (NH 4 PF 6 ), (NH 4 ) 2 TaF 7 , NH 4 NbF 4 , (NH 4 ) 2 GeF 6 , (NH 4 ) Z SmF 6 , (N ⁇ ) 2 TiF 6 , (NH 4 )ZrF 6 , MoF 6 , ReF 6 , SO 2 ClF, F 2 , SiF 4 , SF 6 , ClF 3 , ClF 5 , BrF 5 , IF 7 , NF 3 , HF, BF 3 , NHF
- the fluorinating agent is an ammonium fluoride including a metalloid or nonmetal (e.g., (NHU) 2 PF 6 , (NHU) 2 BF 4 , (NH 4 ) 2 SiF 6 ).
- the molar ratio of fluorine to the first aluminum containing compound (FrAl 1 ) may be from about 0.5:1 to 6:1, or from about 2.5:1 to about 3.5:1 or from about 0.5:1 to about 4:1, for example.
- the fluorinated support may include from about 1 wt.% to about 30 wt.%, or from about 2 wt.% to about 15 wt.%, or from about 2 wt.% to about 10 wt.% or from about 5 wt.% to about 7 wt.% fluorine.
- the support composition has a bonding sequence selected from Si-O-Al-F, F-Si-O-Al or F-Si-O-Al-F, for example.
- the aluminum and fluorine of the support composition are chemically bonded.
- Embodiments of the invention generally include contacting the fluorinated support with a transition metal compound to form a supported catalyst composition.
- Such processes are generally known to ones skilled in the art and may include charging the transition metal compound in an inert solvent. Although the process is discussed below in terms of charging the transition metal compound in an inert solvent, the fluorinated support (either in combination with the transition metal compound or alternatively) may be mixed with the inert solvent to form a support slurry prior to contact with the transition metal compound.
- Methods for supporting transition metal catalysts are generally known in the art. (See, U.S. Patent No. 5,643,847, U.S. Patent No. 09184358 and 09184389, which are incorporated by reference herein.)
- non-polar hydrocarbons can be used as the inert solvent, but any non-polar hydrocarbon selected should remain in liquid form at all relevant reaction temperatures and the ingredients used to form the supported catalyst composition should be at least partially soluble in the non-polar hydrocarbon. Accordingly, the non-polar hydrocarbon is considered to be a solvent herein, even though in certain embodiments the ingredients are only partially soluble in the hydrocarbon.
- Suitable hydrocarbons include substituted and unsubstituted aliphatic hydrocarbons and substituted and unsubstituted aromatic hydrocarbons.
- the inert solvent may include hexane, heptane, octane, decane, toluene, xylene, dichloromethane, chloroform, 1-chlorobutane or combinations thereof.
- the transition metal compound and the fluorinated support may be contacted at a reaction temperature of from about -60 0 C to about 120 0 C or from about -45°C to about 112°C or at a reaction temperature below about 90 0 C, e.g., from about 0 0 C to about 50 0 C, or from about 20 0 C to about 30 0 C or at room temperature, for example, for a time of from about 10 minutes to about 5 hours or from about 30 minutes to about 120 minutes, for example.
- the weight ratio of fluorine to transition metal (F :M) may be from about 1 equivalent to about 20 equivalents or from about 1 to about 5 equivalents, for example.
- the supported catalyst composition includes from about 0.1 wt.% to about 5 wt.% transition metal compound.
- the solvent may be removed from the mixture in a conventional manner, such as by evaporation or filtering, to obtain the dry, supported catalyst composition.
- the supported catalyst composition may be dried in the presence of magnesium sulfate.
- the filtrate, which contains the supported catalyst composition in high purity and yield can, without further processing, be directly used in the polymerization of olefins if the solvent is a hydrocarbon.
- the fluorinated support and the transition metal compound are contacted prior to subsequent polymerization (e.g., prior to entering a reaction vessel.)
- the process may include contacting the fluorinated support with the transition metal in proximity to contact with an olefin monomer ⁇ e.g., contact within a reaction vessel.
- the transition metal compound includes a metallocene catalyst, a late transition metal catalyst, a post metallocene catalyst or combinations thereof.
- Late transition metal catalysts may be characterized generally as transition metal catalysts including late transition metals, such as nickel, iron or palladium, for example.
- Post metallocene catalyst may be characterized generally as transition metal catalysts including Group 4, 5 or 6 metals, for example.
- Metallocene catalysts may be characterized generally as coordination compounds incorporating one or more cyclopentadienyl (Cp) groups (which may be substituted or unsubstituted, each substitution being the same or different) coordinated with a transition metal through ⁇ bonding.
- Cp cyclopentadienyl
- the s ⁇ bstituent groups on Cp may be linear, branched or cyclic hydrocarbyl radicals, for example.
- the cyclic hydrocarbyl radicals may further form other contiguous ring structures, including indenyl, azulenyl and fluorenyl groups, for example. These contiguous ring structures may also be substituted or unsubstituted by hydrocarbyl radicals, such as Ci to C 20 hydrocarbyl radicals, for example.
- a specific, non-limiting, example of a metallocene catalyst is a bulky ligand metallocene compound generally represented by the formula: [L] 1n M[A] n ; wherein L is a bulky ligand, A is a leaving group, M is a transition metal and m and n are such that the total ligand valency corresponds to the transition metal valency.
- L is a bulky ligand
- A is a leaving group
- M is a transition metal
- m and n are such that the total ligand valency corresponds to the transition metal valency.
- m may be from 1 to 3 and n may be from 1 to 3.
- the metal atom "M" of the metallocene catalyst compound may be selected from Groups 3 through 12 atoms and lanthanide Group atoms, or from Groups 3 through 10 atoms or from Sc, Ti, Zr, Hf, V,
- the oxidation state of the metal atom "M" may range from 0 to +7 or is +1 , +2, +3, +4 or +5, for example.
- the bulky ligand generally includes a cyclopentadienyl group (Cp) or a derivative thereof.
- the Cp ligand(s) form at least one chemical bond with the metal atom M to form the
- metalocene catalyst The Cp ligands are distinct from the leaving groups bound to the catalyst compound in that they are not highly susceptible to substitution/abstraction reactions.
- Cp ligands may include ring(s) or ring system(s) including atoms selected from group 13 to 16 atoms, such as carbon, nitrogen, oxygen, silicon, sulfur, phosphorous, germanium, boron, aluminum and combinations thereof, wherein carbon makes up at least
- Non-limiting examples of the ring or ring systems include cyclopentadienyl, cyclopentaphenanthreneyl, indenyl, benzindenyl, fluorenyl, tetrahydroindenyl, octahydrofluorenyl, cyclooctatetraenyl, cyclopentacyclododecene, phenanthrindenyl, 3,4-benzofluorenyl, 9-phenylfluorenyl, 8-H-cyclopent[a]acenaphthylenyl, 7-H-dibenzofluorenyl, indeno[l,2-9]anthrene, thiophenoindenyl, thiophenofluorenyl, hydrogenated versions thereof (e.g., 4,5,6,7-tetrahydroindenyl or "ELjInd”), substituted versions thereof and heterocyclic versions thereof, for
- Cp substituent groups may include hydrogen radicals, alkyls (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, luoromethyl, fluroethyl, difluroethyl, iodopropyl, bromohexyl, benzyl, phenyl, methylphenyl, tert-butylphenyl, chlorobenzyl, ditnethylphosphine and methylphenylphosphine), alkenyls (e.g., 3-butenyl, 2-propenyl and 5-hexenyl), alkynyls, cycloalkyls (e.g., cyclopentyl and cyclohexyl), aryls (e.g., trimethylsilyl, trimethylgermyl, methyldiethylsilyl, acyls, aroyls
- Each leaving group "A" is independently selected and may include any ionic leaving group, such as halogens (e.g., chloride and fluoride), hydrides, Ci to C 12 alkyls (e.g., methyl, ethyl, propyl, phenyl, cyclobutyl, cyclohexyl, heptyl, tolyl, trifluoromethyl, methylphenyl, dimethylphenyl and trimethylphenyl), C 2 to C 12 alkenyls (e.g., C2 to Ce fluoroalkenyls), Ce to C 12 aryls (e.g., C 7 to C 2 o alkylaryls), Ci to Ci 2 alkoxys (e.g., phenoxy, methyoxy, ethyoxy, propoxy and benzoxy), C 6 to Ci ⁇
- halogens e.g., chloride and fluoride
- hydrides Ci to C 12 alkyls (e.
- leaving groups include amines, phosphines, ethers, carboxylates (e.g., Ci to C ⁇ alkylcarboxylates, Ce to C 12 arylcarboxylates and C 7 to Qg alkylarylcarboxylates), dienes, alkenes (e.g., tetramethylene, pentamethylene, methylidene), hydrocarbon radicals having from 1 to 20 carbon atoms (e.g., pentafluorophenyl) and combinations thereof, for example.
- two or more leaving groups form a part of a fused ring or ring system.
- L and A may be bridged to one another to form a bridged metallocene catalyst.
- a bridged metallocene catalyst for example, may be described by the general formula:
- X is a structural bridge
- Cp A and Cp B each denote a cyclopentadienyl group, each being the same or different and which may be either substituted or unsubstituted
- M is a transition metal and A is an alkyl, hydrocarbyl or halogen group and n is an integer between 0 and 4, and either 1 or 2 in a particular embodiment.
- Non-limiting examples of bridging groups "X" include divalent hydrocarbon groups containing at least one Group 13 to 16 atom, such as, but not limited to, at least one of a carbon, oxygen, nitrogen, silicon, aluminum, boron, germanium, tin and combinations thereof; wherein the heteroatom may also be a Ci to C 12 alkyl or aryl group substituted to satisfy a neutral valency.
- the bridging group may also contain substituent groups as defined above including halogen radicals and iron.
- the bridged metallocene catalyst component has two or more bridging groups.
- bridging groups include methylene, ethylene, ethylidene, propylidene, isopropylidene, diphenylmethylene, 1,2-dimethylethylene, 1,2- diphenylethylene, 1,1,2,2-tetramethylethylene, dimethylsilyl, diethylsilyl, methyl-ethylsilyl, trifluoromethylbutylsilyl, bis(trifluoromethyl)silyl, di(n-butyl)silyl, di(n-propyl)silyl, di(i- propyl)silyl, di(n-hexyl)silyl, dicyclohexylsilyl, diphenylsilyl, cyclohexylphenylsilyl, t- butylcyclohexylsilyl, di(t-butylphenyl)silyl, di(p-tolyl)silyl and the corresponding moie
- the bridging group may also be cyclic and include 4 to 10 ring members or 5 to 7 ring members, for example.
- the ring members may be selected from the elements mentioned above and/or from one or more of boron, carbon, silicon, germanium, nitrogen and oxygen, for example.
- Non-limiting examples of ring structures which may be present as or part of the bridging moiety are cyclobutylidene, cyclopentylidene, cyclohexylidene, cycloheptylidene, cyclooctylidene, for example.
- the cyclic bridging groups may be saturated or unsaturated and/or carry one or more s ⁇ bstituents and/or be fused to one or more other ring structures.
- the one or more Cp groups which the above cyclic bridging moieties may optionally be fused to may be saturated or unsaturated.
- these ring structures may themselves be fused, such as, for example, in the case of a naphthyl group.
- the metallocene catalyst includes CpFlu Type catalysts (e.g., a metallocene catalyst wherein the ligand includes a Cp fluorenyl ligand structure) represented by the following formula: wherein Cp is a cyclopentadienyl group, Fl is a fluorenyl group, X is a structural bridge between Cp and Fl, R 1 is a substituent on the Cp, n is 1 or 2, R 2 is a substituent on the Cp at a position which is ortho to the bridge, m is 1 or 2, each R 3 is the same or different and is a hydrocarbyl group having from 1 to 20 carbon atoms with at least one R 3 being substituted in the para position on the fluorenyl group and at least one other R 3 being substituted at an opposed para position on the fluorenyl group and p is 2 or 4.
- Cp is a cyclopentadienyl group
- Fl is a fluorenyl group
- X is
- the metallocene catalyst includes bridged mono-ligand metallocene compounds (e.g., mono cyclopentadienyl catalyst components).
- the metallocene catalyst is a bridged "half-sandwich” metallocene catalyst.
- the at least one metallocene catalyst component is an unbridged "half sandwich” metallocene.
- Non-limiting examples of metallocene catalyst components consistent with the description herein include, for example: cyclopentadienylzirconiumA n , indenylzirconiumAn, (1 -methylindenyl)zirconiumA n , (2-methylindenyl)zirconiumA n , (1 -propylindenyl)zirconiumA n , (2-propylindenyl)zirconiumA n , (1 -butylindenyl)zirconiumA n , (2-butylindenyl)zirconiumA n , methylcyclopentadienylzirconiumA n , tetrahydroindenylzirconiumA n , pentamethylcyclopentadienylzirconiumA n , cyclopentadienylzirconiumA n , pentamethylcyclopentadienyltit
- dimethylsilylbis(cyclopentadienyl)zirconiumA n dimethylsilylbis(9-fluorenyl)zirconiumA n> dimethylsilylbis( 1 -indenyl)zirconiumA n , dimethylsilylbis(2-methylindenyl)zirconiumA n , dimethylsilylbis(2-propylindenyl)zirconiumA n , dimethylsilylbis(2-butylindenyl)zirconiumA n , diphenylsilylbis(2-methylindenyl)zirco ⁇ ivunA n , diphenylsilylbis(2-propylindenyl)zirconiu ⁇ iA n , diphenylsilylbis(2-butylindenyl)zirconiumA ⁇ , dimethylgermylbis(2-methylindenyl)zirconiumA n , dimethylsilylbis(
- the transition metal compound includes cyclopentadienyl ligands, indenyl ligands, fluorenyl ligands, tetrahydroindenyl ligands, alkyls, aryls, amides or combinations thereof.
- the transition metal compound includes a transition metal dichloride, dimethyl or hydride.
- the transition metal compound may have C 1 , C s or C 2 symmetry, for example.
- L is selected from C4 to C 3 0 hydrocarbons, oxygen, nitrogen, phosphorous and combinations thereof.
- M is selected from Group 3 to Group 14 metals, lanthanides, actinides and combinations thereof.
- A is selected from halogens, C 4 to C 30 hydrocarbons and combinations thereof.
- the transition metal compound includes rac- dimethylsilanylbis(2-methyl-4-phenyl-l-indenyl)zirconium dichloride.
- One or more embodiments may further include contacting the fluorinated support with a plurality of catalyst compounds (e.g., a bimetallic catalyst.)
- a bimetallic catalyst means any composition, mixture or system that includes at least two different catalyst compounds, each having a different metal group.
- Each catalyst compound may reside on a single support particle so that the bimetallic catalyst is a supported bimetallic catalyst.
- the term bimetallic catalyst also broadly includes a system or mixture in which one of the catalysts resides on one collection of support particles and another catalyst resides on another collection of support particles.
- the plurality of catalyst components may include any catalyst component known to one skilled in the art, so long as at least one of those catalyst components includes a transition metal compound as described herein.
- contacting the fluorinated support with the transition metal ligand via the methods described herein unexpectedly results in a supported catalyst composition that is active without alkylation processes ⁇ e.g., contact of the catalyst component with an organometallic compound, such as MAO.
- an organometallic compound such as MAO.
- the absence of substances, such as MAO generally results in lower polymer production costs as alumoxanes are expensive compounds. Further, alumoxanes are generally unstable compounds that may require cold storage.
- embodiments of the present invention unexpectedly result in a catalyst composition that may be stored at room temperature for periods of time (e.g., up to 2 months) and then used directly in polymerization reactions. Such storage stability further results in improved catalyst variability as a large batch of support material may be prepared and contacted with a variety of transition metal compounds (which may be formed in small amounts optimized based on the polymer to be formed.)
- polymerizations absent alumoxane activators result in minimal leaching/fouling in comparison with alumoxane based systems.
- embodiments of the invention generally provide processes wherein alumoxanes may be included without detriment.
- the fluorinated support and/or the transition metal compound may be contacted with at least one compound prior to or after contact with one another.
- the at least one compound is generally represented by the formula XR n , wherein X is selected from Group 12 to 13 metals, lanthanide series metals or combinations thereof and each R is independently selected from alkyls, alkoxys, aryls, aryloxys, halogens, hydrides, Group 1 or 2 metals, organic nitrogen compounds, organic phosphorous compounds and combinations thereof and n is from 2 to 5.
- the fluorinated support is contacted with the compound prior to contact with the transition metal compound.
- the fluorinated support may be contacted with the transition metal compound in the presence of the compound.
- the contact may occur by contacting the fluorinated support with the compound at a reaction temperature of from about 0 0 C to about 150 0 C or from about 20 0 C to about 100 0 C for a time of from about 10 minutes hour to about 5 hours or from about 30 minutes to about 120 minutes, for example.
- X includes aluminum.
- the compound may include an organic aluminum compound.
- the organic aluminum compound may include triethyl aluminum (TEAl), triisobutyl aluminum (TEBAl), tri-n-hexyl aluminum (TNHAl), tri- n-octyl aluminum (TNOAl) or tri-isoprenyl aluminum (TISPAl), for example.
- the supported catalyst system is formed in the absence of TIBAl.
- X includes boron.
- the compound may include an organic boron compound, such as a C2 to C3 0 trialkyl boron.
- the compound includes a borate.
- the borate may include a borate salt, such as a lithium borate.
- the weight ratio of the silica to the compound (Si:X 2 ) may be from about 0.01:1 to about 10:1 or from about 0.1:1 to about 7:1, for example.
- the compound generally contacts the fluorinated support (or components thereof) in an amount that is insufficient to alkylate the fluorinated support.
- the compound includes a plurality of compounds.
- the plurality of compounds may include a first compound including aluminum and a second compound including borane.
- the plurality of compounds may include a trialkyl aluminum and a trialkyl borane.
- the compound includes more aluminum than boron.
- the compound may include only a minor amount of boron (e.g., less than about 10 wt.%, or less than about 5 wt.%, or less than about 2.5 wt.% or less than about 1.0 wt.%).
- boron e.g., less than about 10 wt.%, or less than about 5 wt.%, or less than about 2.5 wt.% or less than about 1.0 wt.%.
- the compound may contact the transition metal compound.
- the weight ratio of the compound to transition metal (X 2 :M) may be from about 0.1: to about 5000:1, for example.
- the fluorinated support may be contacted with one or more scavenging compounds and/or anti-fouling agents prior to or during polymerization.
- scavenging compounds is meant to include those compounds effective for removing impurities (e.g., polar impurities) from the subsequent polymerization reaction environment. Impurities may be inadvertently introduced with any of the polymerization reaction components, particularly with solvent, monomer and catalyst feed, and adversely affect catalyst activity and stability. Such impurities may result in decreasing, or even elimination, of catalytic activity, for example.
- the polar impurities or catalyst poisons may include water, oxygen and metal impurities, for example.
- the scavenging compound may include an excess of the first or second aluminum compounds described above, or may be additional known organometallic compounds, such as
- the scavenging compounds may include triethyl aluminum (TMA), triisobutyl aluminum (TIBAl), methylalumoxane (MAO), isobutyl aluminoxane and tri-n-octyl aluminum.
- TMA triethyl aluminum
- TIBAl triisobutyl aluminum
- MAO methylalumoxane
- isobutyl aluminoxane tri-n-octyl aluminum.
- the scavenging compound is TIBAl.
- the amount of scavenging compound is minimized during polymerization to that amount effective to enhance activity and avoided altogether if the feeds and polymerization medium may be sufficiently free of impurities.
- catalyst systems are used to form polyolefin compositions. Once the catalyst system is prepared, as described above and/or as known to one skilled in the art, a variety of processes may be carried out using that composition. The equipment, process conditions, reactants, additives and other materials used in polymerization processes will vary in a given process, depending on the desired composition and properties of the polymer being formed. Such processes may include solution phase, gas phase, slurry phase, bulk phase, high pressure processes or combinations thereof, for example. ⁇ See, U.S. Patent No. 5,525,678, U.S. Patent No. 6,420,580, U.S. Patent No. 6,380,328, U.S. Patent No.
- the processes described above generally include polymerizing olefin monomers to form polymers.
- the olefin monomers may include C 2 to C 3 o olefin monomers, or C 2 to C 12 olefin monomers (e.g., ethylene, propylene, butene, pentene, methylpentene, hexene, octene and decene), for example.
- Other monomers include ethylenically unsaturated monomers, C 4 to C 18 diolef ⁇ ns, conjugated or nonconjugated dienes, polyenes, vinyl monomers and cyclic olefins, for example.
- Non-limiting examples of other monomers may include norbornene, nobornadiene, isobutylene, isoprene, vinylbenzocyclobutane, sytrene, alkyl substituted styrene, ethylidene norbornene, dicyclopentadiene and cyclopentene, for example.
- the formed polymer may include homopolymers, copolymers or terpolymers, for example.
- One example of a gas phase polymerization process includes a continuous cycle system, wherein a cycling gas stream (otherwise known as a recycle stream or fluidizing medium) is heated in a reactor by heat of polymerization. The heat is removed from the cycling gas stream in another part of the cycle by a cooling system external to the reactor.
- the cycling gas stream containing one or more monomers may be continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions.
- the cycling gas stream is generally withdrawn from the fluidized bed and recycled back into the reactor. Simultaneously, polymer product may be withdrawn from the reactor and fresh monomer may be added to replace the polymerized monomer.
- the reactor pressure in a gas phase process may vary from about 100 psig to about 500 psig, or from about 200 psig to about 400 psig or from about 250 psig to about 350 psig, for example.
- the reactor temperature in a gas phase process may vary from about 30 0 C to about 120°C, or from about 60 0 C to about 115°C, or from about 70 0 C to about 110 0 C or from about 70 0 C to about 95°C, for example. (See, for example, U.S. Patent No.
- the polymerization process is a gas phase process and the transition metal compound used to form the supported catalyst composition is CpFIu.
- Slurry phase processes generally include forming a suspension of solid, particulate polymer in a liquid polymerization medium, to which monomers and optionally hydrogen, along with catalyst, are added.
- the suspension (which may include diluents) may be intermittently or continuously removed from the reactor where the volatile components can be separated from the polymer and recycled, optionally after a distillation, to the reactor.
- the liquefied diluent employed in the polymerization medium may include a C 3 to C 7 alkane (e.g., hexane or isobutene), for example.
- the medium employed is generally liquid under the conditions of polymerization and relatively inert.
- a bulk phase process is similar to that of a slurry process. However, a process may be a bulk process, a slurry process or a bulk slurry process, for example. [0082] In a specific embodiment, a slurry process or a bulk process may be carried out continuously in one or more loop reactors.
- the catalyst as slurry or as a dry free flowing powder, may be injected regularly to the reactor loop, which can itself be filled with circulating slurry of growing polymer particles in a diluent, for example.
- hydrogen may be added to the process, such as for molecular weight control of the resultant polymer.
- the loop reactor may be maintained at a pressure of from about 27 bar to about 45 bar and a temperature of from about 38°C to about 121°C, for example.
- Reaction heat may be removed through the loop wall via any method known to one skilled in the art, such as via a double-jacketed pipe.
- other types of polymerization processes may be used, such stirred reactors in series, parallel or combinations thereof, for example.
- the polymer Upon removal from the reactor, the polymer may be passed to a polymer recovery system for further processing, such as addition of additives and/or extrusion, for example.
- the catalyst preparation is an in-situ process. Such process may occur with our without isolation of the fluorinated catalyst. While an increase in catalytic activity has been observed as a result of contacting the supported catalyst system (or components thereof) with the compound represented by the formula XR 3 regardless of isolation, processes utilizing non-isolated catalysts resulted in catalyst activities different than that obtained with isolated catalysts.
- the polymers (and blends thereof) formed via the processes described herein may include, but are not limited to, linear low density polyethylene, elastomers, plastomers, high density polyethylenes, low density polyethylenes, medium density polyethylenes, polypropylene (e.g., syndiotactic, atactic and isotactic) and polypropylene copolymers, for example.
- the polymer includes a bimodal molecular weight distribution.
- the bimodal molecular weight distribution polymer may be formed by a supported catalyst composition including a plurality of transition metal compounds.
- the polymer has a narrow molecular weight distribution ⁇ e.g., a molecular weight distribution of from about 2 to about 4.
- the polymer has a broad molecular weight distribution (e.g., a molecular weight distribution of from about 4 to about 25.)
- the polymers and blends thereof are useful in applications known to one skilled in the art, such as forming operations (e.g., film, sheet, pipe and fiber extrusion and co-extrusion as well as blow molding, injection molding and rotary molding).
- Films include blown or cast films formed by co-extrusion or by lamination useful as shrink film, cling film, stretch film, sealing films, oriented films, snack packaging, heavy duty bags, grocery sacks, baked and frozen food packaging, medical packaging, industrial liners, and membranes, for example, in food-contact and non-food contact application.
- Fibers include melt spinning, solution spinning and melt blown fiber operations for use in woven or non-woven form to make filters, diaper fabrics, medical garments and geotextiles, for example.
- Extruded articles include medical tubing, wire and cable coatings, geomembranes and pond liners, for example. Molded articles include single and multi-layered constructions in the form of bottles, tanks, large hollow articles, rigid food containers and toys, for example.
- alumina-silica support composition refers to alumina-silica that was obtained from Grace Davison (13 wt.% Al).
- Support Preparation Method A The preparation of support material A was achieved by mixing 15.0 g of the alumina-silica support composition in 60 mL of water with 3.1 g OfNH 4 Fl 2 (dissolved in 25 mL of water) within a 250 mL round bottom flask to form a fluorided support including 20 wt.% fluorinating agent. The water was then removed under vacuum at 90 0 C. The resulting solids were then heated in a muffle furnace at 400 0 C for 3 hours.
- Support Preparation Method B The preparation of support material B was achieved by mixing the alumina-silica support composition with Et 3 B in hexane at ambient conditions to form a fluorided support, which was subsequently dried. [0094] The dried support material was then contacted with (NEU) 2 SiFo to form a fluorided support including 20 wt.% fluorinating agent. The resulting solids were then heated under air in a tube furnace at 400 0 C for 2 hours.
- Catalyst Preparation Method A The preparation of support material A was achieved by mixing 15.0 g of the alumina-silica support composition (15 wt.% of alumina) in 60 mL of water with 3.0 g OfNH 4 F 1 HF (dissolved in 25 mL of water) within a 250 mL round bottom flask to form a fluorided support including 20 wt.% fluorinating agent. The water was then removed under vacuum at 90°C. The resulting solids were then heated in a muffle furnace at 400 0 C for 3 hours.
- Support Preparation Method B 3.0 grams of alumina-silica (13 wt.% of alumina) was placed in a 250, 1-neck, schlenk round bottom flask and placed in a glass- drying oven at 145°C for 16 hours. The flask was capped with a rubber septum and placed under vacuum. After the flask cooled to ambient temperature, it was stored in a glove box under nitrogen. [0097] 15.0 grams of the dry alumina-silica was slurried in 30.0 mL of isohexane followed by adding 7.72 mL Et 3 B (Aldrich, IM in Hexane).
- support material B was achieved by mixing the alumina-silica support composition with Et 3 B in hexane at ambient conditions to form a fiuorided support, which was subsequently dried.
- Catalyst Preparation Method C The preparation of Catalyst C was achieved by slurrying a support material in hexane. The slurry was then contacted with Et 3 B (5 wt.%).
- the treated slurry was then filtered and washed with hexane.
- the preparation further included contacting dimethylsilylbis(2-methyl-4-phenyl- l-indenyl)zirconium dichloride with AIR 3 (AlRs/support weight ratio is 1) at ambient conditions.
- the resulting mixture was then added to the slurry to form a supported catalyst system including 1 wt.% metallocene.
- the supported catalyst system was then stirred for 1.0 hour.
- Catalyst Preparation Method D The preparation of Catalyst D was achieved by slurrying a support material (B) in hexane. The slurry was then contacted with TEBAl
- the preparation further included contacting dimethylsilylbis(2-methyl-4-phenyl- l-indenyl)zirconium dichloride with AIR 3 (ALRj/support weight ratio is 0.5) at ambient conditions.
- the resulting mixture was then added to the slurry to form a supported catalyst system including 1 wt.% metallocene.
- the supported catalyst system was then stirred for 30 minutes.
- Catalyst Preparation Method E The preparation of Catalyst E was achieved by slurrying a support material in hexane. The slurry was then contacted with AIR3.
- the preparation further included contacting dimethylsilylbis(2-methyl-4-phenyl- l-indenyl)zirconium dichloride with AIR 3 at ambient conditions. The resulting mixture was then added to the slurry to form a supported catalyst system including 1 wt.% metallocene.
- the supported catalyst system was then stirred for 30 minutes.
- TNHAl tri-n-hexyl aluminum
- TNOAl tri-n-octyl aluminum
- TIBAl tri-iso-butyl aluminum
- TNHAl demonstrated the highest catalyst activity with in-situ catalyst preparation methods.
- Et 3 B triethyl borane
- T 1 . recrystallization temperature
- TM the peak melt temperature
Abstract
Description
Claims
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