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  • 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
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  • 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
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Definitions

• Desirable would be a catalyst composition for production of high stiffness/high melt flow propylene-based polymers that reduces, or eliminates, the risk of reactor disruption, or shut-down due to excessive heat.
• the present disclosure provides a catalyst composition and polymerization process for the production of a propylene-based polymer with a high melt flow rate and high stiffness.
• Trie catalyst composition is self-limiting and exhibits strong hydrogen response with the production of the high melt flow/high stiffness propylene-based polymer under standard polymerization conditions.
• the present disclosure provides a catalyst composition.
• the catalyst composition includes a procatalyst composition, a cocatalyst, and a mixed external electron donor (M- EED).
• the M-EED includes an activity limiting agent (ALA), a first selectivity control agent (SCAl), a second selectivity control agent (SCA2).
• SCAl and SCA2 are present at a mole ratio from 0.1 -1 ,0:1.
• the ALA is selected from an aromatic ester or a derivative thereof, an aliphatic ester or a derivative thereof, a diether, a poly(alkylene glycol) ester, and combinations thereof.
• SCA1 is a dimethoxysiiane.
• SCA2 is selected from a diethoxysilane, a triethoxysilane, a tetraethoxysilane, a trimethoxysilane, a diether, a dialkoxybenzene, a dimethoxysilane containing two linear alkyl groups, a dimethoxysilane containing two alkenyl groups, and combinations thereof.
• a polymerization process which includes contacting propylene and optionally at least one other olefin with a catalyst composition in a polymerization reactor under polymerization conditions.
• the catalyst composition includes the procatalyst, the cocatalyst and the M-EJED.
• the process further includes forming a propylene-based polymer having a melt flow rate of at least 50 g/10 rnin.
• the catalyst composition self limits the polymerization reaction.
• the present disclosure provides a composition.
• a propylene- based polymer is provided which includes at least 5 ppm of the activity limiting agent.
• the propylene-based polymer has a melt flow rate greater than about 50 g/10 min as measured in accordance with ASTM D 1238-01 at 230°C, 2.16 kg.
• An advantage of the present disclosure is the provision of an improved catalyst composition.
• An advantage of the present disclosure is the provision of an improved polymerization process.
• An advantage of the present disclosure is the provision of an improved propylene- based polymer.
• An advantage of the present disclosure is the provision of a catalyst composition that produces a high melt flow/high stiffness propylene-based polymer, the catalyst composition self-limiting the polymerization reaction.
• An advantage of the present disclosure is a process for producing a high melt flow/high stiffness propylene-based polymer with standard amounts of hydrogen, without visbreaking.
• An advantage of the present disclosure is the provision of a propylene-based polymer with high melt flow with one or more of the following properties: high final melting point, low oligomer content, low or no .toxicity, low or no decomposition products, and/or low or no unpleasant odor.
• Figure 1 is a graph showing the final melting temperature and the melt flow rate for a propylene-based polymer.
• Figure 2 is a graph showing the oligomer content and the melt flow rate for a propylene-based polymer.
• a catalyst composition in an embodiment, includes a procatalyst composition, a cocatalyst, and a mixed external electron donor (M- EED).
• the M-EED includes a first selectivity control agent (SCAl), a second selectivity control agent (SCA2) and an activity limiting agent (ALA).
• SCAl selectivity control agent
• SCA2 second selectivity control agent
• ALA activity limiting agent
• SCA1:SCA2 mole ratio from about 0.1:1 to about 1.0:1.
• the M-EiED may include three or more selectivity control agents (SCA3, SCA4, etc.) and/or two or more ALAs,
• the procatalyst composition of the present catalyst composition may be a Zieg ⁇ er- Natta procatalyst composition. Any conventional Ziegler-Natta procatalyst. may be used in the present catalyst composition.
• the Ziegler-Natta procatalyst composition contains a transition metal compound and a Group 2 metal compound.
• the transition metal compound may be a solid complex derived from a transition metal compound, for example, titanium-, zirconium-, chromium- or vanadium-hydrocarbyloxides, hydrocarbyls, halides, or mixtures thereof.
• the transition metal compound has the general formula TrX x where Tr is the transition metal, X is a halogen or a C 1-10 hydrocarboxyl or hydrocarbyl group, and x is the number of such X groups in the compound in combination with a Group 2 metal compound, Tr may be a Group 4, 5 or 6 metal. In an embodiment, Tr is a Group 4 metal, such as titanium. X may be chloride, bromide, C 1-4 alkoxide or phenoxide, or a mixture thereof. In an embodiment, X is chloride.
• Nonlimiting examples of suitable transition metal compounds that may be used to form the Ziegler-Natta procatalyst composition are TiCl 4 , ZrCl 4 , HfCl 4 , TiBr 4 , TiCl 3 , Ti(OC 2 H 5 ) 3 Cl, Zr(OC 2 H 5 ) 3 Cl, Ti(OC 2 H 5 ) 3 Br, Ti(OC 3 H 7 ) 2 Cl 25 Ti(OC 6 H 5 ) 2 Cl 2 , Zr(OC 2 H 5 ) 2 Cl 2 , and Ti(OC 2 H 5 )Cl 3 .
• Mixtures of such transition metal compounds may be used as well. No restriction on the number of transition metal compounds is made as long as at least one transition metal compound is present.
• the transition metal compound is a titanium compound.
• Nonlimiting examples of suitable Group 2 metal compounds include magnesium halides, dialkoxyrnagnesiums, alkoxymagnesium halides, magnesium oxyhalides, ⁇ dialkylmagnesiums, magnesium oxide, magnesium hydroxide, and carhoxylates of magnesium.
• the Group 2 metal compound is magnesium dichloride.
• the Ziegler-Natta procatalyst composition is a mixture of titanium moieties supported on or otherwise derived from magnesium compounds.
• Suitable magnesium compounds include anhydrous magnesium chloride, magnesium chloride addiicts, magnesium dialkoxides or aryloxides, or carboxylated magnesium dialkoxides or aryloxides.
• the magnesium compound is a magnesium di(C 1-4 )alkoxide, such as diethoxyrnagnesium.
• Nonlimiting examples of suitable titanium moieties include titanium alkoxides, titanium aryloxides, and/or titanium halides.
• Compounds used to prepare the Ziegler-Natta procatalyst composition include one or more magnesium-di(Cm)alkoxides, magnesium dihaiides, magnesium alkoxyhalides, or mixtures thereof and one or more titanium tetra(C: ⁇ ) alkoxides, titanium tetrahalides, titanium(C 1-4 )alkoxyhalides, or mixtures thereof.
• a precursor composition may be used to prepare the Ziegler-Natta procatalyst composition as is commonly known in art.
• the precursor composition may be prepared by the ehlorination of the foregoing mixed magnesium compounds, titanium compounds, or mixtures thereof, and may involve the use of one or more compounds, referred to as "clipping agents", that aid in forming or solubilizing specific compositions via a solid/solid metathesis.
• clipping agents include trialkylborates, especially triethylborate, phenolic compounds, especially cresol, and silanes.
• the precursor composition is a mixed magnesium/titanium compound of the formula Mg d Ti(OR e ) f X g wherein E e is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms or COR' wherein R 1 is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms; each OR 3 group is the same or different; X is independently chlorine, bromine or iodine; d is 0.5 to 56, or 2-4; or 3; f is 2-116, or 5-15; and g is 0.5-116, or 1-3, or 2,
• the precursor may be prepared by controlled precipitation through removal of an alcohol from the reaction mixture used in its preparation.
• the reaction medium comprises a mixture of an aromatic liquid, especially a chlorinated aromatic compound, such as chlorobenzene, with an alkanol, especially ethanol, and an inorganic chlorinating agent.
• Suitable inorganic chlorinating agents include chlorine derivatives of silicon, aluminum and titanium, such as titanium tetrachloride or titanium trichloride, and titanium tetrachloride in particular.
• the chlorinating agents lead to partial chlorination which results in a precursor containing relatively high level of alkoxy component(s). Removal of the alkanol from the solution used in the chlorination, results in precipitation of the solid precursor, having a desirable morphology and surface area.
• the precursor was separated from the reaction media.
• the resulting precursor is particularly uniform particle sized and resistant to particle crumbling as well as degradation of the resulting procatalyst.
• the precursor composition is Mg 3 Ti(OEt) 8 Cl 2 .
• the precursor is next convened to a solid procatalyst by further reaction (haiogenation) with an inorganic halide compound, preferably a titanium halide compound, and incorporation of an internal electron donor.
• an inorganic halide compound preferably a titanium halide compound
• incorporation of an internal electron donor may be added separately before, during or after haiogenation. This procedure may be repeated one or more times, optionally in the presence of additional additives or adjuvants, and the final solid product washed with an aliphatic solvent. Any method of making, recovering and storing the solid procatalyst is suitable for use in the present disclosure.
• One suitable method for haiogenation of the precursor is by reacting the precursor at an elevated temperature with a tetr either titanium halide, optionally in the presence of a hydrocarbon or halohydrocarbon diluent.
• the preferred tetr candidate titanium halide is titanium tetrachloride.
• the optional hydrocarbon or halohydrocarbon solvent employed in the production of olefin polymerization procatalyst preferably contains up to 12 carbon atoms inclusive, or up to 9 carbon atoms inclusive.
• Exemplary hydrocarbons include pentane, octane, benzene, toluene, xylene, alkylbenzenes, and decahydronaphthalene.
• Exemplary aliphatic halohydrocarbons include methylene chloride, methylene bromide, chloroform, carbon tetrachloride, 1,2-dibromoethane, 1,1,2-trichloroethane, trichlorocyclohexar.e, dichlorofluoromethane and tetrachlorooctane.
• Exemplary aromatic halohydrocarbons include chlorobenzene, bromobenzene, dichlorobenzenes and chlorotoluenes.
• the aliphatic halohydrocarbon may be a compound containing at least two chloride substituents such as carbon tetrachloride or 1,1,2-trichloroethane.
• the aromatic halohydrocarbon may be chlorobenzene or o-chlorotoluene,
• Tlie halogenation may be repeated one or more times, optionally accompanied by washing with an inert liquid such as an aliphatic or aromatic hydrocarbon or halohydrocarbon between halogenalkms and following halogenation. Further optionally one or more extractions involving contacting with an inert liquid diluent, especially an aliphatic or aromatic hydrocarbon, or aliphatic or aromatic halohydrocarbon, especially at an elevated temperature greater than 100°C., or greater than 110°C, may be employed to remove labile species, especially TiCl 4 .
• the Ziegler-Natta procatalyst composition includes a solid catalyst component obtained by (i) suspending a dialkoxy magnesium in an aromatic hydrocarbon or halohydrocarbon that is liquid at normal temperatures, (ii) contacting the dialkoxy magnesium with a titanium halide and further (iii) contacting the resulting composition a second time with the titanium halide, and contacting the dialkoxy magnesium with a diester of an aromatic dicarboxylic acid at some point during the treatment with the titanium halide in (ii).
• the Ziegler-Natta procatalyst composition includes a solid catalyst component obtained by (i) suspending a precursor material of the formula Mg d TiCOR e ) f X g (as described previously) in an aromatic hydrocarbon or halohydrocarbon that is liquid at normal temperatures, (ii) contacting the precursor with a titanium halide and further (iii) contacting the resulting composition a second time with the titanium halide, and contacting the precursor with a diester of an aromatic dicarboxylic acid at some point during the treatment with the titanium halide in (ii).
• the procatalyst composition includes an internal electron donor.
• an "internal electron donor” is a compound added or otherwise formed during formation of the procatalyst composition that donates a pair of electrons to one or more metals present in the resultant procatalyst composition. Not bounded by any particular theory, it is believed that the internal electron donor assists in regulating the formation of active sites, thereby enhancing catalyst stereoselectivity,
• the internal electron donor is a bidentate compound.
• a "bidentale compound,” as used herein, is a compound containing at least two oxygen- containing functional groups, the oxygen-containing functional groups separated by at least one saturated C 2 -C 10 hydrocarbon chain which may optionally contain heteroatom(s).
• the bidentate compound may be a phthalate, a diether, a succinate, a phenylene dibenzoate, a maleate, a malonate, a glutarate, a dialkoxybenzene, a bis(alkoxyphenyj), a diol ester, a ketoester, an alkoxyaikyl ester, a bis(alkoxyalkyl) fluorene, and any combination thereof.
• the internal electron donor is a phthalate, including diisobutyl phthalate and/or di-n-butyl phthalate.
• the internal electron donor is 9,9-bis(methoxymethyl)-9H- fluorene.
• the internal electron donor is a phenylene dibenzoate.
• the Ziegler-Natta procatalyst composition may also include an inert support material.
• the support may be an inert solid which does not adversely alter the catalytic performance of the transition metal compound.
• Examples include metal oxides, such as alumina, and metalloid oxides, such as silica.
• the present catalyst composition includes a cocatalyst.
• the cocatalyst for use with the foregoing Ziegler-Natta procatalyst composition may be an aluminum containing composition.
• suitable aluminum containing compositions include organoaluminum compounds, such as trialkylal ⁇ minum-, dialkylaluminum hydride-, alkylalurninum dihydride-, dialkylaluminum halide-, alkylaluminumdihalide-, dialkylaluminum alkoxide-, and alkylaluminum dialkoxide- compounds containing from 1- 10, or 1-6 carbon atoms in each alkyl- or alkoxide- group.
• the cocatalyst is a C 1-4 trialkylaluminum compound, such as triethylaluminum (TEA or TEAl).
• TEA triethylaluminum
• the molar ratio of aluminum to titanium is 10-200:1, or 35-50:1. In an embodiment, the molar ratio of aluminum to titanium to 45: 1.
• the present catalyst composition includes a mixed external electron donor
• M-EED which includes a first selectivity control agent (SCAI), a second selectivity control agent (SCA2), and an activity limiting agent (ALA).
• SCAI first selectivity control agent
• SCA2 second selectivity control agent
• ALA activity limiting agent
• an "external electron donor” is a compound added independent of procatalyst formation that contains at least one functional group thai is capable of donating a pair of electrons to a metal atom. Bounded by no particular theory, it is believed that provision of one or more external electron donors in the catalyst composition affects the following properties of the formant polymer: level of tacticity (i.e., xylene soluble material), molecular weight (Le, , meit flow), molecular weight distribution (MWD), melting point, and/or oligomer level.
• level of tacticity i.e., xylene soluble material
• Le, meit flow molecular weight distribution
• MWD molecular weight distribution
• Nonlimiting examples of suitable compounds for the SCA include silicon compounds, such as alkoxysilanes; ethers and polyethers, such as alkyl-, cycloalkyl-, aryl-, mixed alkyl/aryl-, mixed alkyl/cycloalkyl-, and/or mixed cycloalkyl/aryl -ethers and/or polyethers; esters and polyesters, especially alkyl.
• silicon compounds such as alkoxysilanes
• ethers and polyethers such as alkyl-, cycloalkyl-, aryl-, mixed alkyl/aryl-, mixed alkyl/cycloalkyl-, and/or mixed cycloalkyl/aryl -ethers and/or polyethers
• esters and polyesters especially alkyl.
• cycloalkyl- and/or aryl-esters of monocarboxylic or dicarboxylic acids such as aromatic monocarboxyhc- or dicarboxylicacids
• alkyl- or cycloalkyl-ether or thioether derivatives of such esters or polyesters such as alkyl ether derivatives of alkyl esters or diesters of aromatic monocarboxylic or dicarboxylic acids; and Group 15 or 16 heteroatom-substituted derivatives of all of the foregoing
• amine compounds such as cyclic, aliphatic or aromatic amines, more especially pyrrol or pyridine compounds; all of the foregoing SCA's containing from 2 to 60 carbons total and from I to 20 carbons in any alkyl or alkylene group, 3 to 20 carbons in any cycloalkyl or cycloalkylene group, and 6 to 20 carbons in any aryl or arylene group.
• SCAl and/or SCA2 is a silane composition having the general formula (I):
• R independently each occurrence is hydrogen or a hydrocarbyl or an amino group, optionally substituted with one or more substituents containing one or more Group 14, 15, 16, or 17 heteroatoms. R contains up to 20 atoms not counting hydrogen and halogen.
• R 1 is a C ⁇ - ? .o alky! group, and m is 0, 1, or 2,
• R is C 6-12 aryl, alkyl or aralkyl, C 3-12 cycloallyl, C 3-12 branched alkyl, or C 3-12 cyclic amino group
• R 1 is C 1-4 alkyl
• m is 1 or 2.
• SCAl is a dimethoxysiiane.
• the dimethoxysiiane may include a dimethoxysiiane having at least one secondary aikyl and'or a secondary amino group directly bonded to the silicon atom.
• Nonlimiting examples of suitable dimethoxysilanes include dicyciopentyldimethoxysilane, methylcyclohexyldimethoxysilane, diisopropyldimethoxysilane, isopropylisobutyldimethoxysilane, diisobutyldimethoxysilane, t- butylisopropyldimethoxysilane, cyclopentylpyrrolidinodimethoxysilane, bis(pyrrolidino)dimethoxysi]ane, bis(perhydroisoquinolino)dimelhoxysilane, and any combination of the foregoing.
• SCAl is a stiffness-promoting composition.
• stiffness-promoting composition is a composition that, but for operation according to the process conditions of the present disclosure, increases or otherwise enhances the stiffness of a resulting polymer under the polymerization conditions of interest.
• suitable stiffness-promoting include any of the dimethoxysiianes disclosed above,
• SCAl is. djcyclopenlyldimethoxysilane.
• the SCA2 is a silicon compound selected from a diethoxysilane, a triethoxysilane, a tetraethoxysilane, a trimethoxysilane, a dimethoxysiiane containing two linear alkyl groups, a dimethoxysiiane containing two alkenyl groups, a diether, a dialkoxybenzene. and any combination thereof.
• Nonlimiting examples of suitable silicon compounds for SCA2 include dimethyldimethoxysilane, vinylmethyldimethoxysilane, n-oetylmethyldimethoxysilane, n- octadecylxneti'iyldimethoxysilane, methyldimethoxysilane, 3- chloropropylniethyldimethoxysilane, 2- chloroethy ltnethy Idimethoxy silane,ally ldimethoxy siiane, (3,3,3- trifluoropropyl)methyldimelhoxysilane , n-propylmetliyldimethoxysiSane, chloromethylniethyldimethoxysilane, di-n-octyldimethoxysilane, vinyl(chloromethyl)dirnetboxysilane, methylcyclohexyldiethoxysiiane, vinylmethyl
• SCA2 may be methylcyclohexyldiethoxysilane, di- isobutyldiethoxysilane, n-propyltriethoxysilane, tetraethoxysilane, di-n-butyl- dimethoxysilane, benzyltriethoxysilane, but-3-enyItriethoxysilane, l-(triethoxysily!-2- pentene, (iriethoxysilyl)cyclohexane, and any combination of the foregoing.
• the SCA2 is selected from a dimethoxysilane containing two linear alky! groups, a dimethoxysilane containing two alkenyl groups or hydrogen, wherein one or more hydrogen atoms may be substituted by a halogen, and any combination thereof.
• SCA2 may be a diether, a dimer of a diether, a dialkoxybenzene, a dimmer of a dialkoxybenzene, a dialkoxybenzene linked by a linear hydrocarbon group, and any combination thereof. It is noted that the diethers for the ALA set forth below apply equally as nonlimiting examples for the SCA2 diether.
• SCA2 is a melt flow-promoting composition.
• a "melt flow- promoting composition,” as used herein, is a composition that, but for operation according to the process conditions of the present disclosure, increases the melt flow rate of a resulting polymer under the polymerization conditions of interest.
• the melt-flow promoting composition may be any silane composition suitable as SCA2 as disclosed above, a diether, an alkoxybenzene, an ester, a ketone, an amide, and/or an amine.
• the catalyst composition includes a mole ratio of SCAl to SCA2 that is less than or equal to 1, or 0.1-1.0:1.
• the SCAl :SCA2 mole ratio is 0.1-0.9:1, or 0.2-0,5:1. Not bounded by any particular theory, it has been found that maintaining the SCA1:SCA2 mole ratio to less than or equal to 1.0, advantageously enables both SCAs to contribute to the properties of the formant propylene-based polymer.
• the M-EED includes an activity limiting agent (ALA),
• An "activity limiting agent,” as used herein is a material that reduces catalyst activity at elevated temperature, namely, in a polymerization reactor at polymerization conditions at a temperature greater than about 100°C. Provision of the ALA results in a self-limiting catalyst composition.
• a “self-limiting" catalyst composition is a catalyst composition that demonstrates decreased activity at a temperature greater than about 100°C. In other words, “self-limiting” is the decline of catalyst activity when the reaction temperature rises above 100°C compared to the catalyst activity under normal polymerization conditions with reaction temperature usually below 80°C.
• the catalyst composition is said to be "self- limiting.”
• catalyst activities are adjusted to compensate for different monomer concentrations due to temperature. For example, if liquid phase (slurry or solution) polymerization conditions are ixsed, a correction factor to account for reduced propylene solubility in the reaction mixture at elevated temperatures is included. That is, the catalyst activity is "normalized” to compensate for the decreased solubility compared to the lower temperature, especially a 67°C standard.
• the "normalized" activity, at temperature T, or A ⁇ is defined as the measured activity or (weight polymer/weight catalyst/hr) at temperature T, multiplied by a concentration correction factor, [P(67)]/[P(T)], where [P(67)] is the propylene concentration at 67°C and [P(T)] is the propylene concentration at temperature T.
• concentration correction factor [P(67)]/[P(T)]
• the activity at temperature T is multiplied by a ratio of the propylene concentration at 67 °C to the propylene concentration at temperature T.
• the resulting normalized activity (A) adjusted for the decrease in propylene concentration with temperature increase, may be used for comparison of catalyst activities under varylng temperature conditions.
• the correction factors are listed below for the conditions used in the liquid phase polymerization.
• the correction factor assumes that polymerization activity increases linearly with propylene concentration under the conditions employed.
• the correction factor is a function of the solvent or diluent used.
• the correction factors listed above are for a common C 6-10 aliphatic hydrocarbon mixture (IsoparTME, available from Exxon Chemical Company), Under gas phase polymerization conditions, monomer solubility is normally not a factor and activity is generally uncorrected for temperature difference. That is, activity and normalized activity are the same.
• the "normalized activity ratio" is defined as A ⁇ /A 6 7, where A ⁇ is the activity at temperature T and A 67 is the activity at 67°C. This value can be used as an indicator of activity change as a function of temperature. For example, an A:o ⁇ /A67 equal to 0,30 shows that the catalyst activity at 100°C is only 30 percent of the catalyst activity at 67°C. It has been found that at 100°C, an A 100 /A 67 ratio of 35% or less ylelds a catalyst system that is a self-limiting system.
• the ALA may be an aromatic ester or a derivative thereof, an aliphatic ester or derivative thereof, a diether, a poly(alkylene glycol) ester, and combinations thereof.
• suitable aromatic esters include C 1-10 alky! or cycloalkyl esters of aromatic monocarboxylic acids.
• Suitable substituted derivatives thereof include compounds substituted both on the aromatic ring(s) or the ester group with one or more substit ⁇ ents containing one or more Group 14, 15 or 16 heteroatoms, especially oxygen. Examples of such substit ⁇ ents include (poly)alkylether, eycloalkylether, arylether, aralkylether, alkylthioether, arylthioether.
• the aromatic carboxylic acid ester may be a C 1 . 20 hydrocarbyl ester of benzoic acid wherein the hydrocarbyl group is unsubstituted or substituted with one or more Group 14, 15 or 16 heteroatom containing substituents and C 1-20 (poly)hydrocarbyl ether derivatives thereof, or C 1-4 alky!
• the aromatic carboxylic acid ester is ethyl p-ethoxybenzoate.
• tlie ALA is an aliphatic ester.
• the aliphatic ester may be a C 4- C 30 aliphatic acid ester, may be a mono- or a poly- (two or more) ester, may be straight chain or branched, may be saturated or unsaturated, and any combination thereof.
• the .C 4- C30 aliphatic acid ester may also be substituted with one or more Group 14, 15 or 16 heteroatom containing substituents.
• Nonlimi ⁇ ng examples of suitable C 4- C 30 aliphatic acid esters include C 1-20 alkyl esters of aliphatic C 4-30 monocarboxylic acids, C 1-20 alkyl esters of aliphatic C 8-20 monocarboxylic acids, C 1-4 allyl mono- and diesters of aliphatic C 4-20 monocarboxylic acids and dicarboxylic acids, C 1-4 alkyl esters of aliphatic C 8- 20 monocarboxylic acids and dicarboxylic acids, and C 4-20 mono- or poly carboxy late derivatives of C 2-100 (poly)glycols or C 2-100 (poly)glycol ethers.
• the C 4- C30 aliphatic acid ester may be isopropyl myristate and/or di-n-butyl sebacate.
• the ALA is isopropyl myristate.
• the ALA is a diether.
• the diether may be a dialkyl diether represented by the following formula,
• R 1 to R 4 are independently of one another an alkyl, aryl or aralkyl group having up to 20 carbon atoms, which may optionally contain a group 14, 15, 16, or 17 heteroatom, provided that R 1 and R 2 may be a hydrogen atom.
• Nonlimiting examples of suitable dialkyl ether compounds include dimethyl ether, diethyl ether, dibutyl ether, methyl ethyl ether, methyl butyl ether, methyl cyclohexyl ether, 2,2-dimethyl-l ,3- dimethoxypropane, 2,2-diethyl- 1 ,3-dimethoxypropane, 2,2-di-n-butyl- 1 ,3- dimethoxypropane, 2,2 ⁇ diisobutyl-1,3-dimethoxypropane, 2-ethyl-2-n-butyl-l ,3- dimethoxypropane, 2-n-propyI-2-cyclopentyl- 1 ,3-dimethoxypropane, 2,2-dimethyl- 1 ,3 - diethoxypropane, 2-isopropyl-2-isobutyl-1,3-dimsthoxypropane, 2,2-dicyclopenty 3-1
• the ALA is a poly(alkylene glycol) ester.
• suitable po!y(alkyle ⁇ e glycol) esters include poly(alky!ene glycol) mono- or diacetates, poly(alkylene glycol) mono- or di-rayristates, poly(alkylene glycol) mono- or di- laurates, poly(alkylene glycol) mono- or di- oleates, glyceryl tri(acetate), glyceryl tri-ester of C 2 . 40 aliphatic carboxylic acids, and any combination thereof.
• the poly(alkylene glycol) moiety of the poly(alkylene glycol) ester is a poly(ethylene glycol).
• the molar ratio of aluminum to ALA may be 1.4-85:1, or 2.0- 50:1, or 4-30:1.
• all the carboxylate groups are considered effective components.
• a sebacate molecule contains two carboxylate functional groups is considered to have two effective functional molecules.
• the catalyst composition includes a mole ratio of Al to M-EED of 0.5-25:1, or 1.0-20:1, or 1.5-15:1, or less than about 6, or less than about 5, or less than 4.5.
• the A1;M-EED mole ratio is 0.5-4.0:1.
• the AI/M-EED mole ratio of 0.5:1 to 4.0:1 provides a sufficient amount of aluminum to support the polymerization reaction at normal polymerization temperatures.
• at elevated temperature due to a temperature excursion or a process upset, for example
• more aluminum species react with other catalyst components.
• the aluminum deficiency causes a corresponding reduction in the number of electron donors complexed with the duminum.
• the free electron pairs of the non-complexed donors poison the catalyst system, which self limits the reaction.
• total-SCA is the combined amount (in moles) of SCAi and SCA2.
• total-SCA SCAl (mole) + SCA2 (mole).
• the amount of ALA in M-EED enhances catalyst self-limiting capability at elevated temperature, while the amount of SCAl provides stiffness and the amount of SCA2 provides melt flow in the resultant polymer.
• the total-SCA to ALA mole ratio is 0.43-2.33:1, 0.54-1.85:1 , or 0.67-1.5:1.
• the SCAl to total-SCA mole ratio is 0.2-0.5:1, 0.25-0.45:1, or 0.30-0.40:1.
• Applicants have surprisingly and unexpectedly discovered that a controlled mole ratio of: (1) SCAl to SCA2, and/or (2) total-SCA to ALA, and/or (3) SCAl to total-SCA ylelds a resultant polymer with the unique properties of high melt flow and high stiffness in conjunction with the operability property of a self-limiting catalyst.
• the mole ratio of total-SCA to ALA is 0.43-2.33:1 and the mole ratio of SCAl to total-SCA is 0.2-0.5:1.
• the catalyst composition includes a mole ratio of Al to total- SCA of 1.4-85: 1 , or 2.0-50: 1 , or 4.0-30: 1.
• the catalyst composition includes a mole ratio of total-SCA to ALA that is less than 1.0. Surprisingly and unexpectedly, it has been found that maintaining the mole ratio of total-SCA to ALA to less than 1.0 significantly improves reactor operability.
• the M-EEiD comprises dicyclopentyldimethoxysilane (SCAl), a melt-flow promoting composition (SCA2), and isopropyl myristate (ALA).
• SCA2 is selected from methylcyclohexyldiethoxysilane, diisobutyldiethoxysilane, di-n-butyl-dimethoxysilane, n-propyltriethoxysilane, benzyltriethoxysilane, but-3-enyltriethoxysilane, 1 -(triethoxysilyl)-2-pentene,
• the present catalyst composition may comprise two or more embodiments disclosed herein.
• a polymerization process includes contacting propylene and optionally at least one other olefin with a catalyst composition in a polymerization reactor under polymerization conditions.
• the catalyst composition may be any catalyst composition disclosed herein and includes a procatalyst, a cocatalyst and a mixed external electron donor (M-EED) comprising a first selectivity control agent (SCAl), a second selectivity control agent (SCA2), and an activity limiting agent (ALA).
• M-EED mixed external electron donor
• the process also includes forming a propylene-based polymer having a melt flow rate (MFR) of at least 50 g/10 min as measured in accordance with ASTM D 1238-01 test method at 230°C with a 2,16 kg weight
• the process includes forming a propylene-based polymer with a MFR greater than 60 g/10 min, or greater than 70 g/10 min, or greater than 80 g/10 min, or greater than 100 g/10 min, or greater than 50 g/ 10 min to about 1000 g/10 min.
• the process includes contacting propylene and optionally at least one other olefin with the catalyst composition in a polymerization reactor.
• One or more olefin monomers can be introduced into the polymerization reactor along with the propylene to react with the catalyst and to form a polymer, a copolymer, (or a fluidized bed of polymer particles).
• Noniimiting examples of suitable olefin monomers include ethylene, C 4-20 ⁇ -olefins, such as 1-butene, 1-pentene, 1-hexene, 4 ⁇ methyl-1-pentene, 1-heptene, 1-octene, 1-decene, 1- dodecene and the like; C 4-20 dioiefins, such as ⁇ , 3 -butadiene, 1,3-pentadiene, norbornadiene, 5-ethylidene-2-norbornene (ENB) and dicyclopentadiene; C 8-40 vinyl aromatic compounds including styrene, o-, m-, and p-methylstyrene, divinylbenzene, vinylbiphenyl, vinylnapihalene; and halogen-substituted C 8-40 vinyl aromatic compounds such as chlorostyrene and fiuorostyrene.
• C 4-20 ⁇ -olefins such as 1-but
• the process includes contacting propylene with the catalyst composition to form a propylene h ⁇ mopolymer.
• polymerization conditions are temperature and pressure parameters within a polymerization reactor suitable for promoting polymerization between the catalyst composition and an olefin to form the desired polymer.
• the polymerization process may be a gas phase, a slurry, or a bulk polymerization process, operating in one, or more than one, polymerization reactor.
• the polymerization reactor may be a gas phase polymerization reactor, a liquid-phase polymerization reactor, or a combination thereof.
• hydrogen is a chain transfer agent and affects the molecular weight (and correspondingly the melt flow rate) of the resultant polymer.
• polymerization occurs by way of liquid phase polymerization.
• polymerization occurs by way of gas phase polymerization.
• gas phase polymerization is the passage of an ascending fiuidizing medium, the fluidizing medium containing one or more monomers, in the presence of a catalyst through a fluidized bed of polymer particles maintained in a fluidized state by the fluidizing medium.
• Fluidization is a gas-solid contacting process in which a bed of finely divided polymer particles is lifted and agitated by a rising stream of gas. Fluidization occurs in a bed of particulates when an upward flow of fluid through the interstices of the bed of particles attains a pressure differential and frictional resistance increment exceeding particulate weight.
• a “fluidized bed” is a plurality of polymer particles suspended in a fluidized state by a stream of a fluidizing medium
• a “fluidizing medium” is one or more olefin gases, optionally a carrier gas (such as H 2 or N 2 ) and optionally a liquid (such as a hydrocarbon) which ascends through the gas-phase reactor,
• a typical gas-phase polymerization reactor (or gas phase reactor) includes a vessel (i.e., the reactor), the fluidized bed, a distribution plate, inlet and outlet piping, a compressor, a cycle gas cooler or heat exchanger, and a product discharge system.
• the vessel includes a reaction zone and a velocity reduction zone, each of which is located above the distribution plate.
• the bed is located in the reaction zone.
• the fluidizing medium includes propylene gas and at least one other gas such as an olefin and/or a carrier gas such as hydrogen or nitrogen.
• the contacting occurs by way of feeding the catalyst composition into the polymerization reactor and introducing the olefin into the polymerization reactor,
• the process includes contacting the olefin with a cocatalyst.
• the cocatalyst can be mixed with the procatalyst composition (pre-mix) prior to the introduction of the procatalyst composition into the polymerization reactor.
• cocatalyst is added to the polymerization reactor independently of the procatalyst composition. The independent introduction of the cocatalyst into the polymerization reactor can occur simultaneously, or substantially simultaneously, with the procatalyst composition feed.
• the process includes mixing or otherwise combining the M- EED with the procatalyst composition.
• the M-EED can be comp ⁇ exed with the cocatalyst and/or mixed with the procatalyst composition (pre-mix) prior to contact between the catalyst composition and the propylene.
• the M-EED (or individual components thereof) may be added independently to the polymerization reactor.
• the process includes maintaining a SCAl :SCA2 mole ratio of 0.1-1.0:1.
• the process is a gas phase polymerization process and includes maintaining a hydrogen -to -propylene ("H 2 /C 3 ") mole ratio less than 0.30 (i.e., 0.30:1), or less than 0.20, or less than 0.18, or less than 0.16, or less than 0.08 in a gas phase reactor.
• H 2 /C 3 hydrogen -to -propylene
• high melt flow can be achieved by using a high level of hydrogen, it has been found that propylene-based polymers produced by way of a H 2 /C 3 mole ratio greater than 0.30 significantly accelerate an unwanted reaction of hydrogenation of propylene in the presence of oxidized carbon steel of a reactor and reduce catalyst activity.
• the resultant propylene-based polymer formed by way of the present process avoids excessive amounts of catalytic residue as the H 2 /C 3 mole ratio is less than 0.3.
• the process is a gas phase polymerization process as disclosed in copending application (Attorney Docket No. 68345), filed on February 23, 2009, the entire content of which is incorporated by reference herein.
• the gas phase polymerization process includes maintaining a hydrogen partial pressure below about 80 psi, or below about 71 psi, or below about 63 psi.
• the process includes self-limiting the polymerization process when the temperature in the reactor is greater than about 100°C.
• the process includes forming the propylene-based polymer in a single polymerization reactor.
• the process includes forming a propylene-based polymer containing at least, about 5 ppm ALA and a MFR greater than about 50 g/10 rnin.
• the ALA is present in an amount of at least about 5pprn, or at least about 10 ppm, or at least about 20 ppm., or at least about 30 ppm, or at least about 5 pprn to about 150 ppm.
• the ALA is isopropyl rayri state (IPM).
• the process includes forming a propylene- based polymer containing less than about 200 ppm silicon. In a further embodiment, the process includes forming a propylene-based polymer containing less than 200 ppm, or from about 1 ppm to about 200 ppm, or from about 2 ppm to about 100 ppro dicylcopentyldimethoxysilane.
• Applicants have surprisingly and unexpectedly discovered that the presence of the mixed external electron donor provides a catalyst composition that is self-limiting and produces propylene-based polymers with high stiffness and high melt flow in a single polymerization reactor under standard polymerization conditions.
• the ALA improves operability in the polymerization reactor by preventing a run-away reaction, polymer sheeting, and/or polymer agglomeration caused by excessive heat.
• Provision of SCAl and SCA2 enables the formation of a high stiffness (i.e., T MF greater than about 170°C)/high melt flow (i.e., greater than 50, or 60, or 70, or 100 g/10 min) propylene-based polymer with utilization of standard hydrogen levels.
• the present process advantageously produces a propylene-based polymer with high stiffness and high melt flow without visbreaking — a conventional technique for increasing the MFR beyond the hydrogen usage limitations of a reactor-grade high stiffness propylene-based polymer as described previously.
• visbreaking is the thermal and/or chemical degradation of a polymer into smaller polymer chain segments. Visbreaking typically includes placing a polymer (such as polypropylene) in a melt state in the presence of a free radical initiator (such as a peroxide) to degrade the polypropylene into smaller polypropylene chain segments.
• Visbreaking has many side effects such as formation of decomposition products (which oftentimes cause odor and food incompatibility problems), added cost, and a reduction in polymer stiffness. Visbreaking increases the melt flow yet decreases the weight average molecular weight of a polymer. Visbreaking alters the physical and chemical structure of the initial polymer. For example, a visbroken polypropylene homopolymer will exhibit a reduction in physical and/or mechanical properties (Le., a lower tensile modulus, a lower flexural modulus) compared to an uncracked propylene homopolymer with the same MFR.
• the present process forms an uncracked propylene-based polymer.
• a polymer that is "uncracked” has not been subject to a visbreaking procedure.
• an uncracked polymer is a non-thermally and/or non-chemically degraded polymer.
• An uncracked polymer does not exhibit a decline of physical and/or mechanical properties related to molecular weight (such as flexural modulus and/or tensile properties), as does a visbroken polymer at the same MFR.
• an uncracked polymer does not experience decomposition products (which oftentimes cause odor and food incompatibility problems) as does a visbroken polymer,
• the process includes forming propylene-based polymer having one or more of the following properties:, (i) an uncraeked propylene homopolymer; (ii) a MFR greater than 50 g/10 min, or greater than 60 g/10 min, or greater than 70 g/i ⁇ min, or greater than 100 g/10 min ; (iii) a xylene solubles content of less than 4 wt %, or less than 3% wt %, or from about 0.1 wt % to less than 2.0 wt %; (iv) a T MF greater than about 165°C, or greater than 170°C; (v) an ALA content at least about 5 ppm to about 150 ppm; (vi) a post-reactor oligomer content (“oligomers" are C 12 - C 21 compounds) less than 3000 ppm, or less than 2500 ppm, or from about 500 ppm to about 3000 ppm; and
• post-reactor oligomer content is the oligomer content of the resultant propylene-based polymer immediately after exit from the polymerization reactor.
• post-reactor oligomer content is the oligomer content prior to any post-polymerization washing procedure, heating procedure, and/or refining procedure.
• the present polymerization process may comprise two or more embodiments disclosed herein.
• a propylene-based polymer includes at least 5 ppm of an activity limiting agent.
• the propylene-based polymer has a melt flow rate greater than about 50 g/10 min.
• the ALA may be present in an amount of at least 5ppm. or at least 10 ppm, or at least 20 ppm, or at least about 30 ppm, or at least about 5 ppm to about 150 ppm.
• the ALA is isopropyl myristate (IPM).
• the propylene-based polymer has a MFR greater than 60 g/10 min, or greater than 70 g/10 min, or greater than 80 g/10 min, or greater than 100 g/10 min, or greater than 50 g/ 10 min to about 1000 g/10 min.
• the propylene-based polymer is uncracked.
• the propylene-based polymer is a propylene homopolymer.
• the propylene-based polymer includes less than about 200 ppm silicon, or from about 1 ppm to about 200 ppm, or from about 2 ppm to about i00 pprn silicon. In a further embodiment, the propylene-based polymer includes from about 1 ppm to about 200 ppm dicylcopentyldimethoxysiiane.
• the propylene-based polymer includes a property selected from: (i) a xylene solubles content of less than about 4 wt %, or less than about 3% wt %, or from about 0.1 wt % to less than about 2.0 wt %; (ii) a T MF greater than about 165°C, or greater than about 170°C; (iii) a post-reactor oligomer content less than about 3000 ppm, or less than about 2500 ppm, or from about 500 ppm to about 3000 ppm; and (iv) any combination of (i)-(iii).
• the present propylene-based polymer has low or no toxicity, low or no decomposition products, and/or low or no unpleasant odor.
• the present propylene-based polymer may comprise two or more embodiments disclosed herein.
• references to the Periodic Table of the Elements herein shall refer to the Periodic Table of the Elements, published and copyrighted by CRC Press, In ⁇ , 2003. Also, any references to a Group or Groups shall be to the Groups or Groups reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups.
• compositions claimed herein through use of the term “comprising” may include any additional additive, adjuvant, or compound whether polymeric or otherwise, unless stated to the contrary.
• any numerical range recited herein includes all values from the lower value to the upper value, in increments of one unit, provided that there is a separation of at least 2 units between any lower value and any higher value.
• amount of a component, or a value of a compositional or a physical property such as, for example, amount of a blend component, softening temperature, melt index, etc.
• amount of a blend component, softening temperature, melt index, etc. is between 1 and 100
• all individual values, such as, 1, 2, 3, etc., and all subranges, such as, 1 to 20, 55 to 70, 197 to 100, etc. are expressly enumerated in this specification.
• one unit is considered to be 0.0001, 0.001.
• blend or "polymer blend,” as used herein, is a blend of two or more polymers. Such a blend may or may not be miscible (not phase separated at molecular level). Such a blend may or may not be phase separated. Such a blend may or may not contain one or more domain configurations, as determined lrom transmission electron spectroscopy, light scattering, x-ray scattering, and other methods known in the art.
• composition includes a mixture of materials which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.
• polymer is a macr ⁇ molecular compound prepared by polymerizing monomers of the same or different type.
• Polymer includes homopolymers, copolymers, terpolymers, interpolyiners, and so on.
• interpolymer means a polymer prepared by the polymerization of at least two types of monomers or comonomers.
• copolymers which usually refers to polymers prepared from two different types of monomers or comonomers
• terpolymers which usually refers to polymers prepared from three different types of monomers or comonomers
• tetrapolymers which usually refers to polymers prepared from four different types of monomers or comonomers
• interpolymer refers to polymers prepared by the polymerization of at least two different types of monomers.
• the generic term interpolymer thus includes copolymers, usually employed to refer to polymers prepared from two different monomers, and polymers prepared from more than two different types of monomers.
• olefin-based polymer is a polymer containing, in polymerized form, a majority weight percent of an olefin, for example ethylene or propylene, based on the total weight of the polymer.
• olefin-based polymers include ethylene- based polymers and propylene-based polymers.
• ethylene-based polymer refers to a polymer that comprises a majority weight percent polymerized ethylene monomer (based on the total weight of polymerizable monomers), and optionally may comprise at least one polymerized comonomer.
• propylene-based polymer refers to a polymer that comprises a majority weight percent polymerized propylene monomer (based on the total amount of polymerizable. monomers), and optionally may comprise at least one polymerized comonomer.
• alkyl refers to a branched or unbranched, saturated or unsaturated acyclic hydrocarbon radical.
• suitable alkyl radicals include, for example, methyl, ethyl, n-propyl, i-propyl, 2-propenyl (or allyl), vinyl, n-butyl, t- butyl, i-butyl (or 2-methylpropyl), etc.
• the alky Is have 1 and 20 carbon atoms.
• substituted alkyl refers to an alkyl as just described in which one or more hydrogen atom bound to any carbon of the alkyl is replaced by another group such as a halogen, aryl, substituted aryl, cycloaikyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, halogen, haloalkyl, hydroxy, amino, phosphide, alkoxy, amino, thio, nitro, and combinations thereof.
• Suitable substituted alky Is include, for example, benzyl, trifluoromethyl and the like.
• aryl refers to an aromatic substituent which may be a single aromatic ring or multiple aromatic rings which are fused together, linked covalently, or linked to a common group such as a methylene or ethylene moiety.
• the aromatic ring(s) may include phenyl, naphtfayl, anthraeenyl, and biphenyl, among others.
• the aryls have 1 and 20 carbon atoms.
• Flexural modulus is determined in accordance with ASTM D790-00.
• Melt flow rate is measured in accordance with ASTM D 1238-01 test method at 230° with a 2.16 kg weight for propylene-based polymers.
• Xylene Solubles is measured using a 1 H NNOl method as described in U.S. Pat. No. 5,539,309, the entire content of which is incorporated herein by reference.
• TMF Final melting point
• Sample preparation Compression mold 1.5 g of powder sample using a 30-G302H-18-CX Wabash Compression Molder (30 ton): (a) heat mixture at 230 °C for 2 minutes at contact; (b) compress the sample at the same temperature with 20 ton pressure for 1 minute; (c) cool the sample to 45°F and hold for 2 minutes with 20 ton pressure; (d) cut the plaque into 4 of about the same size, stack them together, and repeat steps (a) - (c) in order to homogenize sample.
• 30-G302H-18-CX Wabash Compression Molder (30 ton): (a) heat mixture at 230 °C for 2 minutes at contact; (b) compress the sample at the same temperature with 20 ton pressure for 1 minute; (c) cool the sample to 45°F and hold for 2 minutes with 20 ton pressure; (d) cut the plaque into 4 of about the same size, stack them together, and repeat steps (a) - (c) in order to homogenize sample.
• [00.132] (4) Weigh a piece of sample (preferably between 5 to 8 mg) from the sample plaque and seal it in a standard aluminum sample pan, Place the sealed pan containing the sample on the sample side of the instrument head/cell and place an empty sealed pan in the reference side. If using the auto sampler, weigh out several different sample specimens and set up the machine for a sequence.
• a piece of sample preferably between 5 to 8 mg
• TMF is determined by the interception of two lines. Draw one line from the base-line of high temperature. Draw another line from through the deflection of the curve close to the end of the curve at high temperature side.
• Oligomer content testing method Oligomer content is measured by extracting a polymer sample overnight in a chloroform solution containing n-hexadecane as an internal standard. An aliquot of the extract is shaken with methanol and then filtered to remove any precipitated high molecular weight polypropylene and solid particles. The filtered liquid is injected onto a fused silica capillary chromatography column using cold on-column injection, Relative amounts of the extracted components are calculated based on the weight of polymer extracted.
• Procatalyst VlOB is a commercial SHACTM 320 catalyst containing 2.52 wt% of Ti and 10.34 wt% of di-isobutyl phthalate (DiBP).
• Procatalyst 1910-29-2 is prepared according to the procedure for catalyst 4949-25-1 in U.S. Provisional Patent Application No. 61/141,902 filed on December 31, 2008, the entire content of which is incorporated by reference herein.
• Procatalyst 1910-29-2 contains 3.61 wt % of Ti and 14.85 wt % of 3-methyl-5-tert ⁇ butyl-1,2-phenylene dibenzoate,
• IPM isopropyl myrisiate
• PTES n-propy ltriethoxysilane S-191 ... POE (15) coco fatty acids ester S1B0971.0: benzyJtriethoxysilane SIB 1928.0: butenyltriethoxysilane TEOS: tetraethoxysilane
• Liquid Phase Polymerization is performed in liquid propylene in a 1 -gallon autoclave. After conditioning, the reactors are charged with 1375 g of propylene and a targeted amount of hydrogen and brought to 62°C. External electron donor component(s) is added to a 0.27-M triethylaiuminum solution in isooctane and a 5.0 wt% catalyst slurry in mineral oil (as indicated in data tables below) and premixed at ambient temperature for 20 minutes before being injected into the reactor to initiate the polymerization. The premixed catalyst components are flushed into the reactor with is ⁇ oetane using a high pressure catalyst injection pump. After the exothe ⁇ n, the temperature is controlled to 67°C. Total polymerization time is 1 hour.
• Procatalyst A commercial SHACTM 320 catalyst (2.59% Ti) and DiBP is used. Catalyst slurries are prepared in toluene at 0.247 mg/rn.1. Al! SCAS and ALAs are diluted to 0.005 M in Isopar ETM, except S-191 which is dissolved in toluene before injection into the PPRs. TEAl is prepared in Isopar ETM and used as either 0.02 or 0.1M solutions,
• the self-limiting property of the present catalyst composition is also observed for other SCA1/SCA2/ALA systems composed of alkylalkoxysilanes such as DiPDMS/TEOS, DCPDMS/TEOS, and DCPDMS/MChDMS in the presence of and ALA, such as PEEB.
• PEEB is replaced with a poly(alkylene glycol) ester compound, such as S-191
• the self-limiting effect is profound (Table 8) even at higher A1/M-EED molar ratio.
• Similar results are observed when the ALA is isopropyl myristate (IPM).
• Catalyst compositions containing an M-EED as disclosed herein are self-limiting systems while simultaneously retaining the advantages of multiple SCAs. Provision of a melt flow-promoting composition such as SCA2 increases the MFR of the resultant polymer, Catalyst compositions with a M-EED produce a polymers with a stiffness substantially the same as, or the same as, the polymer stiffness resulting from a catalyst composition having a stiffness-promoting composition (such as dicylcopentyldimethoxysilane) as fee only external electron donor. Provision of a stiffness-promoting composition such as SCAl produces a polymer with high stiffness as exemplified by the T MF values in Tables 2-7.
• a stiffness-promoting composition such as SCAl produces a polymer with high stiffness as exemplified by the T MF values in Tables 2-7.
• Total oligomer content for polymers produced with the present catalyst composition is significantly reduced compared to the oligomer content when a stiffiiess- promoting composition (such as dicyclopentylditnethoxysilane) is used as the sole external donor at the same melt flow.
• a stiffiiess- promoting composition such as dicyclopentylditnethoxysilane
• the present polymers are not visbroken and have high melt flow, high stiffness as well as low oligomer content, low or no toxicity, and/or low or no decomposition products.

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