Title of Invention

IMPROVED ACIDIC ACTIVATOR-SUPPORTS AND CATALYSTS FOR OLEFIN POLYMERIZATION

Abstract This invention relates to me field qf olefin polymerization catalyst compositions, and methods for the polymerization and copplymerization of olefins, typically using a supported catalyst composition. In one aspect, this invention encompasses precontacting a metallocene with an olefin or atkyne monomer and an prganpaluminum compound, prior to contacting this mixture with the acidic activator-support
Full Text CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Patent Application Serial No. 10/877,039 entitled "Improved Acidic Activator-Supports 'and Catalysts for Olefin Polymerization," which was filed on June 25, 2004 and is incorporated by reference herein in its entirety.
TECHNICAL FIELD OF THE INVENTION."
This invention relates to the field of olefin polymerization catalyst compositions, methods for the polymerization of olefins, and olefin polymers.
BACKGROUND OF THE INVENTION
Mono-1-olefins (a-olefins), including ethylene, can be polymerized with catalyst compositions employing titanium, zirconium, vanadium, chromium or other metals, impregnated on a. variety of support materials, often in the presence of cocatalysts. These catalyst compositions may be useful for both homopolymerization of ethylene, as well as copolymerization of ethylene with comonomers such as propylene, 1-butene, 1-hexene, or oier higher a-olefins. Therefore, there.exists a constant .search to develop new olefin polymerization catalysts, catalyst.activation .processes, and methods of making and using catalysts that will provide enhanced catalytic activities and polymeric materials tailored to specific end uses.
One type of catalyst system comprises organometal compounds, particularly metallocene compounds. It is known that contacting water with trimefhylaluminum under appropriate conditions forms methyl aluijainoxane; and subsequently contacting methyl aluminoxane with a metallocene compound forms a metallocene polymerization catalyst. However, in order to achieve the desired high polymerization activities, large amounts of methyl aluminoxane, and hence large amounts of expensive trimethylaluminum, are nscessary to form the active metallocene catalysts. This feature has been an/impediment to the commercialization of •metallocene catalyst .'systems, therefore improvements in catalyst compositions and in methods of making the catalyst are needed to afford the desired high polymerization activities.
What are needed are new catalyst compositions and methods of making the catalyst compositions that afford high polymerization activities, and will allow polymer properties to be maintained within the desired specification ranges. One method to achieve this goal is to develop new polymerization methods that provide and utilize catalysts of sufficiently high activity as to be commercially viable.
DESCRIPTION OF THE INVENTION •
This invention comprises catalyst compositions, methods for preparing catalyst compositions, and methods for polymerizing olefins and acetylenes using the catalyst compositions. In the course of examining-metallocene olefin polymerization catalysts, it was discovered that increased activity in metalldcene catalyst compositions could be achieved by precontacting the metallocene compound- with an alkene or alkyne monomer and an organoaluminum cocatalyst for some period of .time before the mixture is contacted with an aiidic activator-support.
The mixture of at least one metallocene, alkene or alkyne monomer, and organoaluminum cocatalyst compound, before it is contacted with the activator-support, is termed the "precontacted" mixture. The mixture of metallocene, monomer, organoalumimun cocatalyst, and activator-support, formed from contacting the precontacted mixture with the acidic activator-support, is termed the "postcpntacted" mixture. This terminology is used regardless of what type of reaction oc.curs .between components of the mixtures. For example, according to this description, it is possible for. the precontacted organoaluminum compound, once it is admixed with the metallocene or metallocenes and the olefin or alkyne monomer, to have a different chemical formulation, and structure from the distinct organoaluminum compound used to prepare the precontacted mixture. Accordingly, the metallocene, the organoalurrununi: compound,::the olefin or alkyne, and the acidic activator-svpport, whether precontacted or postcontacted, are described according to the corresponding metallocene, organoaluminum compound/ olefin or alkyne, and acidic activator-support used to contact the other components rapreparing the precontacted or postcontacted mixtures.
. Therefore, in one aspect, the catalyst.composition of this invention comprises: at least one precontacted metallocene; at least one .pireppntacted organoaluminum compound; at least ore precontacted olefin or alkyne; and at least one postcontacted acidic activator-support.
In another aspect, the precontacted metallocene comprises a compound having the fbllowingfornv'1"'
wherein M1 is comprising titanium, zirconium, or hafnium;
wherein (X1) is independently comprising cyclopentadienyl, indenyl, fluorenyl,
boratabenzene, substituted cyclopentadienyl, substituted indenyl, substituted fluorenyl, or
substituted boratabenzene; ' ' ...-•= • •
wherein each substituent on the substituted cyclopentadienyl, substituted indenyl,
substituted fluorenyl or substituted boratabenzene of (X1) is independently comprising an
aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic
groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic
group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron
group, an aluminum group, -an inorganic; group, an organometallic group, or a substituted
derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or
hydrogen;
wherein at least one substituent on (X1) is optionally a bridging group that connects
(X1) and (X2); ' .
wherein (X3) and (X4) are independently an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having
s
from 1 to 20 carbon atoms; or a halide.
wherein (X2) is independently a cyciopentadienyl group, an indenyl group, a fluorenyl
group, a boratabenzene group, an aliphatic -group; an aromatic group, a cyclic group, a
combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen
group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium
group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an
organometallic group, or a substituted derivative thereof, any one of which having from 1 to
20 carbon atoms; or a halide;
wherein each substituent on the substituted (X2) is independently an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon
group, a silicon group, a germanium group, a. tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen; and wherein at least one substituent on (X2) is optionally a bridging group that connects (X1) and (X2).
In another aspect of this. invention;.: tfce precontaoted organoaluminum compound comprises an organoaluminum compouhd-with the following formula:
wherein (X5) is a hydrocarbyl having from 2 to 20 carbon atoms; (X*) is an alkoxide or aryloxide, any one of which having from 1 tp. 20 carbon atoms, halide, or hydride; and n is a number from 1 to 3, inclusive.
In still another aspect of the invention, the precontacted olefin or alkyne comprises a compound having from 2 to 30 carbon atoms per molecule and having at least one carbon-carbon double bond or at least one carbon-carbon triple bond.
Yet another aspect of this invention''!? the postcontacted acidic activator-support that comprises a solid oxide treated with an electron-withdrawing anion, wherein:
the solid oxide is silica, •alumina, silica-alumina, aluminum phosphate, heteropolytungstates, titania, zarconia, magnesia, boria, zinc oxide, mixed oxides thereof, or mixtures thereof; and
the electron-withdrawing anion is 'fluoride, chloride, bromide, phosphate, triflate, bisulfate, sulfate, or any combination thereof. : '
In one aspect of this invention, for example, the metallocene compound comprises a zirconium metallocene such as 6is(indenyl)zirconium dichloride (IndzZrCy or &w(cyclopentadienyl)zirconium dichloride (CpzZrCk), which is employed along with triethylaluminum cocatalyst and a fluoride-treated silica-alumina acidic activator-support. The activator-support of this invention, of which fluo'rided silica-alumina is one example, exhibits enhanced acidity as compared to the corresponding untreated solid oxide compound. The activator-support also functions as a catalyst activator as compared to the corresponding untreated solid -oxide. Accordingly, the acidic activator-support functions as an "activator"
because it is not merely an inert support component of the catalyst composition, but is involved in effecting the observed catalytic chemistry.
In another aspect of this invention, for example, precontacting a metallocene compound with 1-hexene and triethylaluminum, typically for at least 10 minutes, prior to contacting this mixture with-the acidic activator-support such as fluorided silica-alumina, the productivity of the subsequent olefin polymerization was increased by several-fold as compared to a catalyst composition using'-the 'same components, but without a precontacting step. The enhanced activity catalyst composition of this invention can be used for liomopolymerization of an ccrolefin monomer, for copolymerization.of an cc-olefin and a comonomer, and for polymerization of alkynes as. well.
This invention also comprises methods of making catalyst compositions that utilize at least one metallocene catalyst, at least one! ofganoaluminum compound as cocatalysts, and an acidic activator-support. The methods of this invention comprise precontacting the metallocene catalyst and an organoaluminum cocatalyst with an olefin or alkyne compound typically, but not necessarily,, a.monomer- tb-"be-polymerized or copolymerized, prior to contacting this precontacted mixture with: tbie. acidic activator-support. Such methods allow ::br, among other things, attaining a high polymerization activity and productivity.
Thus, in one aspect, this invention provides a process to produce a catalyst composition, comprising:
contacting at least one metallocene, at least one organoaluminum compound, and at least one olefin or alkyne for a first period of time to form a precontacted mixture comprising at least one precontacted metallocene, at least one precontacted organoaluminum compound, and at least one precontacted olefin or alkyne; and
contacting the precontacted mixture with at least one acidic activator-support for a second .period of time to form a pqstcontacted mixture comprising at least one
- ' , .' •.,'_ •
postcontacted metallocene, at least one- postcphtacted 'organoaluminum compound, at least one postcontacted olefin or alkyne, and at least one postcontacted acidic activator-support.
Further, this invention encompasses a catalyst composition' that comprises cyclic organoaluminum compounds, particularly, aluminacyclopentanes, that derive from precontacting an organoaluminum cocatalyst with an unsaturated compound. This invention also comprises a method of preparing a 'catalyst'composition that generates cyclic
cirganoaluminum compounds from precontacting an organoaluminum cocatalyst with an imsaturated compound.
The present invention further comprises new catalyst compositions, methods for preparing catalyst compositions, and methods for polymerizing olefins or alkynes that result in improved productivity, without the need for using large excess concentrations of expensive cirganoaluminum cocatalysts.
Additionally, this invention encompasses a process comprising contacting at least one monomer and the catalyst composition under polymerization conditions to produce the polymer. Thus, this invention comprises njejhi&ds for .polymerizing olefins and alkynes using the catalyst compositions prepared as described herein.
This invention also comprises an article that comprises the polymer produced with the catalyst composition of this invention.
These and other features, aspects,, embodiments, and advantages of the present hvention will become apparent after a--review of the 'following detailed description of the disclosed features.
The following patent 'applications, filed contemporaneously with the present application, are incorporated by reference herein in their entireties: U.S. Patent. Application No. 10/876,930; .U.S. Patent Application.; No! 10/876,891;'U.S. Patent Application No. 10/876,948; and U.S. Patent Application N6;10/877,021.'
The present invention provides new catalyst compositions, methods for preparing catalyst compositions, and methods for using the catalyst compositions to polymerize olefins and acetylenes. In one aspect, the catalyst composition of this invention comprises: at least one precontacted metallocene; at least one. precontacted orgaribaluminum compound; at least one precontacted olefih or alkyrie; and at least One postcohtacted acidic activator-support.
In yet another aspect, the present invention provides a catalyst composition comprising an optional cocatalyst in addition to the precontacted metallocene, precontacted organoaluminum compound, precontacted olefin or alkyne, and postcontacted acidic activator-support. In ones aspect, the optional cocatalyst may be at least one aluminoxane, at loast one organoboron compound, at least o'ne-ionizing1 ionic compound, or any combination
thereof. In another aspect, the optional cocatalyst may be used in the precontacting step, in Ihe postcontacting step, or in both steps. Further, any combination of cocatalysts may be used in either step, or in both steps.
In still another aspect, this invention provides a process to produce a catalyst composition, comprising:
contacting a metallocene, an organoaluminum compound, and an olefin or alkyne for a first period of time to form a precontacted mixture comprising a precontacted metallocene, a precontacted organoalurnirjopi. compound, and a precontacted olefin or uthylene; and
contacting the precontacted mixture with a acidic activator-support for a second period of time to form a postcontacted mixture comprising a postcontacted metallocene, a postcontacted organoaluminum compound, a postcontacted olefin or alkyne, iind a postcontacted acidic activator-support.
Catalyst Compositions and Components .„;'•'
The Metallocene Compound
The present invention provides catalyst compositions comprising at least one metallocene compound, at least one •organoaluminum compound, at least one olefin or alkyne, and at least one acidic activator-support. In one aspect, the metallocene compound and the organoaluminum compound, are preeontacted with the olefin or alkyne to form a precontacted mixture, prior to contacting this precontacted mixture with the acidic activator-uupport. The metallocene compound may comprise a metallocene compound of titanium, idrconium, and hafnium.
In one aspect; the metallocene compound that is used to prepare the precontacted mixture, comprises a compound haying the'following formula:
wherein M1 is titanium, zirconium, or hafnium;
wherein (X1) is independently cyclopentadienyl, indenyl, fluorenyl, boratabenzene,
.•substituted cyclopentadienyl, substituted indenyl, substituted fluorenyl, or substituted
boratabenzene; ' ', •
wherein each substituent. on the substituted cyclopentadienyl, substituted indenyl, substituted fluorenyl or substituted boratabenzene of (X1) is independently an aliphatic group,
£.n aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative liiereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen;
wherein at least one substituent on (X1) is optionally a bridging group .that connects (X1) and (X2);
wherein (X3) and (X4) are independently, an aliphatic group, an aromatic group, a. cyclic group, a combination of aliphatic .and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide.
wherein (X2) is independently a cyclorjentadienyl group, an indenyl group, a fluorenyl group, a boratabenzene group, an aliphatic/group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic -group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide; . ..' . , .,•:". . ,
wherein each substituent on the substituted (X2.) is independently an aliphatic group, an aromatic group, a cyclic group, a combination = of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a- phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a. tin group, a lead group, a boron group, an aluminum group, an inorganic group, an. qrganometallic group, or a substituted derivative thereof, any one of which having from 1 to "20 'carbon atoms; a halide; or hydrogen; and
wherein at least one substituent on (X2) is optionally a bridging group that connects
In one aspect, the following groups may be independently selected as substituents on (X1) and (X2), or may be independently selected as the (X2), (X3), or (X4) ligand themselves: an aliphatic group, an aromatic group, a cyclte group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron
group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide; as long as these groups do not terminate the activity of the catalyst composition. This list includes substituents that may be characterized in more than one of these categories such as benzyl. Further, hydrogen may be selected as a substituent on (X1) and (X2), as long as these groups do not terminate the activity of the catalyst composition, therefore the notion of a substituted indenyl. and substituted fluorenyl includes partially saturated indenyls and fluorenyls including, but not limited to,, tetrahydroindenyls, tetrahydrofluorenyls, and octahydrofluorenyls.
Examples of each.of these groups include, but are not limited to, the following groups. In each example presented below, unless otherwise specified, R is independently: an aliphatic group; an aromatic group; a cyclic'group; any combination thereof; any substituted derivative thereof, including but not limited' to, a halide-, an alkoxide-, or an amide-substituted derivative thereof; any one of which has from 1 to 20 carbon atoms; or hydrogen. Also included in these groups are any unsubstituted, branched, or linear analogs thereof.
i
Examples of aliphatic groups, in each instance, include, but are not limited to, an alkyl group, a cycloalkyl group, an alkenyl group, a cycloalkenyl group, an alkynyl group, an alkadienyl group, a cyclic aliphatic group, and the like, and includes all substituted, unsubstituted, branched, and linear.analogs, or derivatives thereof, in each instance having from one to 20 carbon atoms. Thus, aliphatic groups include, but are not limited to, hydrocarbyls such as paraffins and alkenyls. For example, aliphatic groups as used herein include methyl, ethyl, propyl, n-butyl, tert-butyl, sec-butyl, isobutyl, amyl, isoamyl, hexyl, cyclohexyl, heptyl, octyl, nonyl, decylj dodecyl;,2-ethylhexyl, pentenyl, butenyl, and the like.
Examples of aromatic groups, in each instance, include, but are not limited to, phenyl, naphthyl, anthacenyl, and the like, including substituted derivatives thereof, in each instance having from 6 to 25 carbons. Substituted derivatives of aromatic compounds include, but are not limited to, tolyl, xylyl, mesityl, and.the like, including any heteroatom substituted derivative thereof.
Examples of cyclic groups, in -each instance, include, but are not limited to, cycloparafflns, cycloolefins, cycloalkynes; aryl groups such as phenyl, bicyclic groups and tiie like, including substituted derivatives thereof, in each instance having from 3 to 20 carbon
E.toms. Thus heteroatom-substituted cyclic groups such as furanyl are included herein. Also included herein are cyclic hydrocarbyl groups such as aryl, cycloalkyl, cycloalkenyl, cycloalkadienyl, aralkyl, aralkenyl, aralkynyl, and the like.
hi each instance, aliphatic and cyclic groups are groups comprising an aliphatic
portion and a cyclic portion, examples -of which include, but are not limited to, groups such
as: -(CHymCeHqRs-q wherein m is an integer from I to 10, q is an integer from 1 to 5,
inclusive; (CH2)mC6HqRio-q wherein m is an integer from 1 to 10, q is an integer from 1 to 10,
inclusive; and (CH^mCsHqRg-q wherein mis an integer from 1 to 10, q is an integer from 1 to
£', inclusive. In each instance and as defined above, R is independently : an aliphatic group;
an aromatic group; a cyclic group; any combination thereof; any substituted derivative
thereof, including but not limited to, a .halide-, an alkoxide-, or an amide-substituted
derivative thereof; any one of which, has from 1 to 20 carbon atoms; or hydrogen. In one
aspect, aliphatic and cyclic groups include, but are not limited to: -
CH2C6H4C1; -CH2C6H4Br; -CH2C6H4l; -CHzCeKtOMe; -CHaCeHUO
CH2C6H4NMe2; -CH2QH4NEt2; -CH2CH2C6HS; -CH2CH2C6H4F;
CH2CH2C6H4Br; • -CB&B£&4h . ; :CHiCH2C6H4OMe;
CH2CH2C6H4NH2; -CH2CH2C6H4NMe2; •-(e%GH2C6H4NEt2; any regioisomer thereof, and
any substituted derivative thereof. . • .
Examples of halides, in each instance, include fluoride, chloride, bromide, and iodide.
In each instance, oxygen groups are oxygen-containing groups, examples of which include, but are not limited to, alkoxy or arytoxy groups (-OR), -OC(O)R, -OC(0)H, -OSiRS, -OPR2, -OA1R2, and the like, including .substituted derivatives thereof, wherein R in each instance is alkyl, cycloalkyl, aryl, aralkyi, substituted alkyl, substituted aryl, or substituted aralkyl having from 1 to. 20 carbon atoms. Examples of alkoxy or aryloxy groups (-OR) groups include, but are not limited to, • methoxy, ethoxy, propoxy, butoxy, phenoxy, substituted phenoxy, and the like.
In each instance, sulfur grou^a €»».« auuiu-uOiiiaiiimg giuups, examples 01 wmcn include, but are not limited to, -SR, - OS02R, -OSO2OR, -SCN, -SO2R, and the like, including substituted derivatives thereof, wherein R in each instance is an alkyl, cycloalkyl, aryl, aralkyl, substituted alkvl. substituted arvl nr nnhQtihit/>H nraiin/i inm/^ncT fmm 1 t« on carbon atoms.
In each instance, nitrogen groups are nitrogen-containing groups, which include, but are not limited to, -NH2, -NHR, -NRz, -NOa, -Nj, and the like, including substituted derivatives thereof, wherein R in each instance is an alkyl, cycloalkyl, aryl, aralkyl, substituted alkyl, substituted aryl, or substituted aralkyl having from 1 to 20 carbon atoms.
In each instance, phosphorus groups are phosphorus-containing groups, which
include, but are not limited to, -PEE, -PHR, -PR2, -P(O)R2, -P(OR)2, -P(O)(OR)2, and the
like, including substituted derivatives thereof, wherein R in each instance is an alkyl,
cycloalkyl, aryl, aralkyl, substituted alkyl; substituted aryl, or substituted aralkyl having from
1 to 20 carbon atoms. '•..'•
In each instance, arsenic, groups are arsenic-contairiing groups, which include, but are
not limited to, -AsHR, -AsR2, -As(O)R2, rAs(OR)2, -As(O)(OR)2, and the like, including
substituted derivatives thereof, wherein R in each instance is an alkyl, cycloalkyl, aryl,
aralkyl, substituted alkyl, substituted aryl, or substituted aralkyl having from 1 to 20 carbon
items. ;
In.each instance, carbon groups are carBpn-containing groups, which include, but are not limited to, alkyl halide groups that comprise halide-substituted alkyl groups with 1 to 20 carbon atoms, aralkyl groups with 1 to 20 carbon atoms, -C(O)H, -C(O)R, -C(O)OR, cyano, -C(NR)H, -C(NR)R, -C(NR)OR, and the- like, including substituted derivatives thereof, wherein R in each instance is an alkyl, cycloalkyl, aryl, aralkyl, substituted alkyl, substituted aryl, or substituted aralkyl having from lto: 20 carbon atoms.
In each instance, silicon groups are'fsHicori-conlaining groups, which include, but are not limited to, silyl groups such alkylsilyl groups, arylsilyl groups, arylalkylsilyl groups, siloxy groups, and the like, which in each instance have from 1 to 20 carbon atoms. For example, silicon groups include trimethylsilyl and phenyloctylsilyl groups.
In each instance, germanium grptips ate germanium-containing groups, which
':''•'' '.'
include, but are not limited to, gerrnyl groups "such •alkylgermyl groups, arylgermyl groups,
arylalkylgermyl groups, germyloxy groups, and the like, which in each instance have from 1
to 20 carbon atoms. : •
In each instance, tin groups are tin-containing groups, which include, but are not limited to, stannyl groups such alkylstaniiyl groups, arylstannyl groups, arylalkylstannyl
groups, stannoxy (or "stannyloxy") groups, and the like, which in each instance have from 1 :o 20 carbon atoms. Thus, tin groups include, but are not limited to, stannoxy groups.
In each instance, lead groups are lead-containing groups, which include, but are not limited to, alkyllead groups, aryllead groups, arylalkyllead groups, and the like, which in each instance, have from 1 to 20 carbon'atoms.
In each instance, boron groups are boron-containing groups, which include, but are not limited to, -BR2, -BX2, -BRX, wherein X is a monoanionic group such as halide, hydride, alkoxide, alkyl thiolate, and the-like, and wherein R in each instance is an alkyl, cycloalkyl, aryl, aralkyl, substituted alkyk&jibstituted aryl, or substituted aralkyl having from 1 to 20 carbon atoms.
In each instance, aluminum groups are aluminum-containing groups, which include, but are not limited to, -A1R2, -AlXa, -A1RX, wherein X is a monoanionic group such as halide, hydride, alkoxide, alkyl thiolate, and the like, and wherein R in each instance is an alkyl, cycloalkyl, aryl, aralkyl, substituted" alkyl, substituted aryl, or substituted aralkyl
having from 1 to 20 carbon atoms. • ..'•'•'
Examples of inorganic groups that may be used as substituents for substituted cyclopentadienyls, substituted indenyls, substituted fluorenyls, and substituted boratabenzenes, in each instance, include, but, are not limited to, -S02X, -OA1X2, -OSiX3, -OPX2, -SX, - OSO2X, -AsX2, -As(0)X Z^-pX^-and the like, wherein X is a monoanionic group such as halide, hydride, amide,, alkoxidfe, alkyl tbiolate; and the like, and wherein any alkyl, cycloalkyl, aryl, aralkyi, substituted alkyl, substituted aryl, or substituted aralkyl group or substituent on these ligands has from 1 to 20 carbon atoms.
Examples of organometallic- groups that may be used as substituents for substituted cyclopentadienyls, substituted indenyls, and 'substituted fluorenyls, in each instance, include, but are not limited to, organoboron groups^ urganodluminum groups, organogallium groups, ' organosilicon groups, organogermanium groups, organotin groups, organolead groups, organo-transition metal groups, and the like, having from 1 to 20 carbon atoms.
In one aspect of this invention, (X3) and (X4) are halides or hydrocarbyls having from 1 to 10 carbon atoms. More" typicallyi- pG) and (X4) are fluoro, chloro, or methyl.
In another aspect, because of the selections, possible for (XI) and (X2), the metallocene of this invention can comprise a monokis(cyclopenta-dienyl) compound, a bis(cyclopentadienyl) compound, a monokis(indenyl) compound, a bis(indenyl) compound, a monokis(fluorenyl) compound, a bis(fluorenyl) compound, a (cyclopentadienyl)(indenyl) compound, a (cyclopentadienyl)-(fluorenyl) compound, an (indenyl)(fluorenyl) compound, substituted analogs thereof, bridged analogs thereof, and the like. Thus, at least one substituent on (X2) is optionally a bridging group that connects (X1) and (X2).
In one aspect of the invention, (X1) is- independently a cyclopentadienyl, indenyl, fluorenyl, boratabenzene, substituted eyclbpentadienyl, substituted indenyl, substituted fluorenyl, or substituted boratabenzene; and (X2) is independently a cyclopentadienyl group, an indenyl group, a fluorenyl group, a boratabenzene group, an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a. carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organprnetallic group, or: a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide; as long as these groups do not terminate the activity of the catalyst composition.
At least one -substituent on (X1) or (X2) may optionally be a bridging group that connects or bridges the (X1) and (X2) ligands, as long as the bridging group does not
• .•;•.. " 12
terminate the activity of the catalyst composition.. The linkage that connects (X ) and (X ), that is, the shortest link of the bridging moiety, can be a single atom selected from carbon, silicon, germanium, or tin atom. In one aspect, the bridging atom is a carbon or silicon atom, in which case the bridge comprises a substituted methylene (or methylidene) group or a substituted silylene group. In another aspect; .the linkage that connects (X1) and {X2), that is, the shortest link of the bridging moiety, can toe from 2 to 4 atoms. In yet another aspect, the linkage that connects (X1) and (X2), that is, the shortest link of the bridging moiety, can comprise from 2 to 4 carbon atoms.
In another aspect, examples of bridging groups include, but are not limited to, aliphatic groups, cyclic groups, combinations .of aliphatic groups and cyclic groups, phosphorous groups, nitrogen groups, brganpmetallic groups, silicon, phosphorus, boron, germanium, and the like. Examples of aliphatic groups that can serve as bridges between (X1) and (X2) include, but are not limited to, hydracarbyls, such as paraffins and olefins.
Examples of cyclic groups that can serve as bridges between (X1) and (X2) include, bur are noi: limited to, cycloparaffins, cycloolefins, cycloalkynes, arenes, and the like. Examples of orj;anometallic groups that can serve as bridges between (X1) and (X2) include, but are not limited to, substituted silyl derivatives, substituted tin groups, substituted germanium groups, substituted boron groups, and the like.
In another aspect, the optional bridging group may be substituted by at least one substituent, wherein the substituent may be independently an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen.
Numerous processes to prepare organometal compounds that can be employed in this invention, particularly metallocenes, have .been, reported. For example, U.S. Patent Nos. 4,939,217, 5,210,352, 5,436,305, 5,401,817^ 5,631,335, 5,571,880, 5,191,132, 5,399,636, 5,fi65,592, 5,347,026, 5,594,078, 5,498,581, 5,496,781, 5,563,284, 5,554,795, 5,420,320, 5,451,649, 5,541,272, 5,705,578, 5,631,20$, 5,654,454, 5,705,579, and 5,668,230 describe such methods, each of which is incorporated -by- reference herein, in its entirety. Other processes to prepare metallocene compounds !that can' be employed in this invention have besn reported in references such as: Kfippl,. A. Alt, H. G. J. Mol. Catal A. 2001, 165, 23; Kj.jigaeshi, S.; Kadowaki, T.; Nishida, A.; Fujisaki, S. The Chemical Society of Japan, 1986, 59, 97; Alt, H. G.; Jung, M.; Kehr, G. J. Organomet. Chem. 1998, 562, 153-181; and Alt, H. G.; Jung, M. /. Organomet. Chem. 1998, 5.68f 87-112; each of which is incorporated by reference herein, in its entirety. Further; ^additional processes to prepare metallocene compounds that can be employed in this, invention have been reported in: Journal of Organometallic Chemistry, 1996, 522, 39-54, which is incorporated by reference herein, in its entirety. The following treatises also describe such methods: Wailes, P. C.; Courts, R. S. P.; Weigold, H. in Organometallic Chemistry of Titanium, Zirconium, and Hafnium, Academic; New York, 1974.; Cardin, D. J;; Lappert, M. F.; and Raston, C. L.; Chemistry of Oigano-Zirconium and -Hafnium Compounid$; Halstead Press; New York, 1986; each of which is incorporated by reference herein, in-its entirety.
In one aspect of this invention, the metallocene compounds of the present invention include, but are not limited to the following-compounds:
bis(cyclopentadienyl)hamiumdichloride,
bis(n-butylcyclopentadienyl)zirconium; dichloride,

dimethylsilylbis(T)5-4,5,6,7-tetrahydro-i-indenyl)zirconium dichloride,
(Figure Remove)


methyl-3-butenylmethylidene(iis-cyclopentadJenyl)(Ti5-2,7-di-f-butyl-9-fluorenyl)-
raethyl-4-pentenylmethylidene(Ti5-cyclopentadienyl)(Ti5-9-fluorenyl)zirconiuin clichloride, [(r) 5-C5H4)CCH3(CH2CH2CH2CHK:H2)(Ti 5-9-Ci jH9)]ZrCl2;
methyl-4-pentenylrael:hylidene(ri5-ciycl6pentadienyl)(ri5-2,7-di-?-butyl-9-.-nuorenyljzirconium dichloride, [(T]5-C5H4)CCH3(CH2CH2CH2CH=CH2)(Ti5-9-Ci3H7-2,7-'Bu2)]ZrCl2;
phenyl-3-butenylmetiiylidene(Tif-cyciopeiitadienyl)(Tis-9-fluorenyl)zirconiuni dichloride, [(TI 5-C5H4}C(C6H5)(CH2CH2CH=CH2)(Ti ^-CnHg^ZrCfc;
phenyl-3-butenylmethyHden£!(ii5.-cyclop.entadienyl)(r)S-2,7-di-f-bu1yl-9-f]uorenyl)zirconimn dicHoride, [{TisrC5H4)C(C6H5)(CH2CH2CH=CH2)(ris-9-CnH7-2,7-'Bu2)]ZrCl2;
phenyl-4-pentenylmethylidene(T)s-cyclopentadienyl)(ri5-9-fluorenyl)zirconium dichloride, [(ri5-CsH4)C(C6Hs)(CH2CH2CH2CH=CH2)(ris-9-Ci3H9)]ZrCl2;
phenyl-4-pentenylraeth.ylidene(Tis-oyclopentadienyl)('n5-2,7-di-f-butyl-9-fluorenyl)-zirconium dichloride, . [(Ti5-Cs]BU)C(C6H5)(ck2CH2CH2CH=CH2)(Ti5-9-Ci3H7-2J7-
and the like.
In yet another aspect of this invention* examples of the metallocene that are useful in the catalyst composition of this invention include a compound with the formula I:

wherein E is C, Si, Ge, or Sn; Rl is H or-a hydrocarbyl group having from 1 to 12 carbon atcms; R2 is an alkenyl group having 'from 3 to 12 carbon atoms; and R3 is H or a hydrocarbyl group having from 1 to 12 carbon atoms.
• •' •
In another aspect, the catalyst composition of this invention comprises a metallocene compound described by structure II as follows:

(Figure Remove)


wherein Rl is methyl or phenyl; R2 is .3-butenyl (-CHaCHkCEHCHa) or 4-pentenyl (-CH2CH2CH2CH=CH2); and R3 is H or fcbutyl. .
Typically, the organometal.' .."eompound ' comprises. bis(n-butylcyclopenta-dienyl)zirconium dichloride; bis(indenyl)zirconium dichloride; dimethylsilylbis(l-indenyl) zirconium dichloride; methyloctylsilylbis(9rtluorenyl)zirconium dichloride; or bis(2,7-di-tert-buiylfluorenyl)-ethan-l ,2-diyl)zirconium(IV) dichloride.
Thz Organoaluminum Compound
In one aspect, the present ihventibn.ptpvides catalyst compositions comprising at least om; metallocene compound, at least one; organoaluminum compound, at least one olefin or alkyne, and at least one acidic activator-support. In another one aspect, the metallocene compound and the organoaluminum.compound are precontacted with the olefin or alkyne to form a precontacted mixture, prior to contacting this precontacted mixture with the acidic
activator-support. Typically, a portion pf the organoaluminum compound is added to the prucontacted mixture and another portion of the organoaluminum compound is added to the postcontacted mixture, although all the organoaluminum compound may be used to prepare the catalyst in the precontacting step.
In another aspect of this invention,'the precontacted mixture can comprise a first organoaluminum compound in addition-to at least one metallocene and an olefin or acetylene monomer, and the postcontacted mixture can comprise a second organoaluminum compound in addition to the precontacted .mixture .and the acidic activator-support. The second organoaluminum compound .can be the. same or. different .from the .first organoaluminum compound. Specifically, any of the possible first organoaluminum compounds may also be ussd as choices for the second brgahoalumimim 'compound, however not all of the possible second organoaluminum compounds work well as choices for the first organoaluminum compound for use in the precontacted mixture.
In yet another aspect, the first organoaluminum compound that can be used in this invention in the precontacted mixture with-fhe metallocene compound and an olefin or alkyne monomer includes, but is not limited to, a compound having the following general formula:
Al(X5)n(X6)3.n,
wherein (X5) is a hydrocarbyl having from 2 to 20 carbon atoms, and (X6) is alkoxide or aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride; and n is a nvmber from 1 to 3, inclusive. In one aspect,'(Xs) is ah alkyl having from 2 to 10 carbon atoms, and in another aspect, (Xs) is ethyl,':propyl; n-butyl, sec-butyl, isobutyl, hexyl, and the like.
The substituent (X6) in the formula for the first organoaluminum compound is alcoxide or aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride. In one aspect, (X6) is independently fluord'6rchlor9,.and in another aspect, (X6) is chloro.
In the formula Al(X5)n(X6)3.d"for the first organoaluminum compound, n is a number from 1 to 3 inclusive, and typically, n is 3. The value of n is not restricted to be an integer, therefore this formula includes sesquihalide compounds.
In yet another aspect, the second organoaluminum compound that can be used in the postcontacted mixture, that is,.in the subsequent contacting of the precontacted components
with additional organoaluminum compound and the activator-support, includes, but is not limited to, a compound having the following general formula:
Al(X5)n(X6)3.n>
wherein (X5) is a hydrocarbyl having from -1 to 20 carbon atoms, and (X6) is an alkoxide or aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride; and n is a number from 1 to 3, inclusive. In one aspect, (Xs) is an alkyl having from 1 to 10 carbon atoms, and in another aspect, (Xs) is methyl, ethyl, propyl, n-butyl, sec-butyl, isobutyl, hexyl, and the like.
The substituent (X6) in the formula-Ji>i;.the second organoaluminum compound is an alkoxide or aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride. In one aspect, (X6) is independently an fluoro or chloro, and in another aspect, (X6) is chloro.
In the second organoaluminum compound formula Al(X5)n(X6)3.n, n is a number from 1 to 3 inclusive, and typically, n is 3. The value of n is not restricted to be an integer, thsrefore this formula includes sesquihalide •compounds.
Generally, examples of organoajuminum compounds that can be used in this invention include, but are not limited to, trialkylaluminum compounds, dialkylaluminium hslide compounds, alkylaluminum dihaJide compounds, alkylaiuminum sesquihalide compounds, and combinations thereof. Specific examples of organoaluminum compounds that can be used in this invention in-the-preconjacted mixture with the organometal compound and an olefin or alkyne monomer rncludfe'/but are not limited to, triethylaluminum (TEA); tripropylaluminum; diethylaluminum ethbxide;' tributylaluminum; diisobutylaluminum hydride; triisobutylaluminum; and diethylaluminum chloride.
When the precontacted mixture comprises a first organoaluminum compound and the postcontacted mixture comprises a second^ organoaluminum compound, any of the possible first organoaluminum compounds rtiay. also ' be used as choices for the second organoaluminum compound. However,''not all of the possible second organoaluminum compounds work well for use in the precontacted mixture. For example, triethyl aluminum (TEA) works well in both precontacted and postcontacted mixtures, however trimethyl aluminum (TMA) works well only in. .the postcontacted mixture and not well in the precontacted mixture. In this example, ofgafioalumrnum compounds that can be used as the second organoaluminum compound in the postcontacted mixture include, but are not limited
to, all the compounds that can be used in the precontacted mixture, and further including trimethylaluminum (TMA).
The amounts of organoaluminum compound disclosed herein include the total amount of organoaluminum compound used in both the precontacted and postcontacted mixtures, and any additional organoaluminum compound, added to the polymerization reactor. Therefore, total amounts of organoaluminum compounds are disclosed, regardless of whether a single organoaluminum compound, is used, or more than one organoaluminum compound. Triethylalurm'num (TEA) is a typical compound used in this aspect of this invention when only a single organoaluminum compound isierp.p.l6yed. ,
Tfie Olefin or Acetylene Monomer
In the present invention, at least one organoaluminum compound, at least one metallocene compound, and at least one olefin or alkyne monomer are precontacted prior to contacting this mixture with a solid acidic activator-support, in order to afford an active
polymerization catalyst.
i
Unsaturated reactants that are useful in the precontacting step and in the polymerization processes with .catalyst compositions of this invention include olefin compounds having from 2 to 30 carbon .atoms per molecule and having at least one olefinic double bond. This invention encompasses. nQmopolymerization processes using a single olefin, as well as copc-lymerization reacti(!)ps;-;mth at least one different olefinic compound. Typically, copolymers of ethylene comprise, a'major amount of ethylene (>50 mole percent) and a minor amount of comonomer Acyclic, cyclic, pplycyclic, terminal ..(a)| internal, linear, branched, substituted, unsubstituted, functionalized, and non?functionalized olefins may be employed in this invention. For example, typical unsaturated compounds that can be polymerized with the catalysts of this invention include, but are not limited to, propylene,. 1-butene, 2-butene, 3-methyl-1-butene, isobutylene, 1-pentene, 2-pentene, 3-methyl-l-pentene, 4-methyl-l-•pentene, 1-hexene, 2-hexene, 3-hexene, .'3-ethyl-l-hexene, 1-heptene, 2-heptene, 3-heptene, the four normal octenes, the four normal hpnenes, the five normal decenes, and mixtures of any two or more thereof. Cyclic and bicyclic olefins, including but not limited to,
cyclopentene, cyclohexene, norbornylene, norbomadiene, and the like, may also be polymerized as described above.
Acetylenes may be also be polymerized according to this invention. Acyclic, cyclic, terminal, internal, linear, branched, substituted, unsubstituted, functionalized, and non-functionalized alkynes may be employed in this invention. Examples of alkynes that can be polymerized include, but are not limited to, diphenylacetylene, 2-butyne, 2-hexyne, 3-hexyne, 2-heptyne, 3-heptyne, 2-octyne, 3-octynej 4Tp.ctyne, and the like.
In one aspect, when a copolyrher is desired, the monomer ethylene may be copolymerized with a comonomer. In another aspect, examples of the comonomer include, but are not limited to, propylene, 1-butenei 2-butene, 3-methyl-l-butene, isobutylene, 1-pcntene, 2-pentene, 3-methyl-l-pentene, 4-methyl-l-pentene, 1-hexene, 2-hexene, 3-hexene, 3-ethyl-l-hexene, 1-heptene, 2-heptene, 3-heptene, the four normal octenes, the four normal nonenes, or the five normal decenes. 'In another aspect, the comonomer may be 1-butene, 1-pontene, 1-hexene, 1-octene, 1-decene, or styrene.
In one aspect, the amount of comonbmer introduced into a reactor zone to produce the copolymer is generally from 0.01 to 10 weight percent comonomer based on the total weight oi' the monomer and comonomer. In another aspect, the amount of comonomer introduced into a reactor zone is from 0.01 to 5 weigijtpercent comonomer, and in still another aspect, from 0.1 to 4 weight percent, comonomer based on .the total weight of the monomer and comonomer. Alternatively, an amount sufficient to give the above described concentrations by weight, in the copolymer produced can be used.
While not intending to -be bound .by this theory,- in the event that branched, substituted, or functionalized olefins are used-as'reactants, it is believed that steric hindrance may impede and/or slow the polymeri2atiori. process. Thus, branched and/or cyclic portion(s) of the olefin removed somewhat from the.carbon-carbon double bond would not be expected to hinder the reaction in the way that the same olefin substituents situated more proximate to the carbon-carbon double bond might. In one aspect, at least one reactant for the catalyst compositions of this invention is . ethylene, so the' polymerizations are either hcmopolymerizations or copolymerizations-with a different acyclic, cyclic, terminal, internal, linear, branched, substituted, or unsubstitiited olefin. In addition, the catalyst compositions of
this invention may be used in polymerization of diolefin compounds, including but are not limited to, 1,3-butadiene, isoprene, 1,4-pentadjene, and 1,5-hexadiene.
The Solid Acidic Activator-Support
The present invention provides catalyst compositions comprising at least one
mcitallocene compound, at least one organpaluminum compound, at least one olefin or
allryne, and at least one acidic activator-support. In one aspect, the metallocene compound
and the organoaluminum compound are prec'ontacted'with the olefin or alkyne to form a
procontacted mixture, prior to contacting this precontacted mixture with the acidic activator-
support. • . .
The present invention encompasses catalyst compositions comprising an acidic acrivator-support, methods for preparing, catalyst compositions comprising an acidic activator-support, and methods for polymerizing olefins and acetylenes using these catalyst compositions. In this invention, the metallocene compound may be contacted with an olofinic or acetylenic monomer and an organoaluminum compound for a first period of time pr.or to contacting this mixture with the-acidic activator-support. Once the precontacted mixture of metallocene, unsaturated monomer, and organoaluminum compound has been
contacted with the acidic activator-s.upporti/this pomposition, which further comprises the
'.'•" '"•• acidic activator-support, is termed the "postcbntacted" mixture. In . one aspect, the
pcstcontacted mixture may be further allowed to remain in contact for a second period of time prior to being charged into the reactor in which the polymerization process will be carried out. In another aspect, the postebhtacted mixture may be charged into the reactor immediately after being prepared, or may "be prepared, directly in the reactor, and the polymerization reaction initiated immediately-thereafter. In this aspect, the second period of time during which the postcontacted mixture'is allowed to remain in contact is the minimal amount of time required to prepare the postcontacted mixture and initiate the polymerization process.
In one aspect, the present invention.encompasses catalyst compositions comprising a chemically-treated solid oxide which serves .as an acidic' activator-support, and which is typically used in combination with an orgarioaluminum compound. In another aspect, the activator-support comprises at least one solid oxide treated with-at least one electron-withdrawing anion; wherein the solid-oxide is silica, alumina, silica-alumina, aluminum phosphate, heteropolytungstates, titania, zirconia, magnesia, boria, zinc oxide, mixed oxides
thereof, or mixtures thereof; and wherein the' electron-withdrawing anion is fluoride, chloride, bromide, phosphate, triflate, bisuliate, sulfate, or any .combination thereof.
The activator-support includes the contact product of at least one solid oxide compound and at least one electron-withdrawing anion source. In one aspect, the solid oxide compound comprises an inorganic oxide. It is not required that the solid oxide compound be calcined prior to contacting the electron-withdrawing anion source. The contact product may be calcined either during or after the solid', oxide compound is contacted with the electron-withdrawing anion source. In this aspeeti the solid oxide compound may be calcined or uncalcined. In another aspect, the activators-support may comprise the contact.product of at least one calcined solid oxide compound and at least one electron-withdrawing anion source.
The activator-support exhibits enh.anc.ed acidity as compared to the corresponding untreated solid oxide compound. The activator-support also functions as a catalyst activator as compared to the corresponding untreated solid oxide. While not intending to be bound by ttieory, it is believed that the activator-support may function as an ionizing solid oxide compound by completely or partially extracting an anionic ligand from the metallocene. However, the activator-support is an- activator regardless of .whether it ionizes the metallocene, abstracts an anionic ligand to. form an-ion pair, weakens the metal-ligand bond in the metallocene, simply coordinates to an anionic ligand when it contacts the activator-support, or any other mechanisms by which activation may occur. While the activator-iiupport activates the metallocene in the absence of cocatalysts, it is not necessary to eliminate oocatalysts from the catalyst composition. The activation function of the activator-support is evident in the enhanced activity of catalyst cpinposjition as a whole, as compared to a catalyst composition containing the corresponding untreated solid oxide. However, it is believed ^at i;he activator-support functions as an activator, even in the absence of an organoaluminum compound, aluminoxanes, organoboron compounds, or ionizing ionic compounds.
In one aspect, the activator-support of this invention comprises a solid inorganic oxide material, a mixed oxide material, or a combination of inorganic oxide materials, that is :hemically-treated with an electron-withdrawing component, and optionally treated with a metal. Thus, the solid oxide of this invention encompasses oxide materials such as alumina, "mixed oxide" compounds thereof such as.^silica-alumina, and combinations and mixtures thereof. The mixed oxide compounds such as • silica-alumina single chemical phases witt
more than one metal combined with oxygen to form a solid oxide compound, and are encompassed by this invention.
In one aspect of this invention, the activator-support further comprises a metal or metal ion selected from zinc, nickel, vanadium, silver, copper, gallium, tin, tungsten, molybdenum, or any combination thereof;'. Examples of activator-supports that further comprise a metal or metal ion include, -but are not limited to, zinc-impregnated chlorided alumina, zinc-impregnated fluorided alumina, zinc-impregnated chlorided silica-alumina, zinc-impregnated fluorided silica-aluminai zinc-impregnated sulfated alumina, or any combination thereof.
In another aspect, the activator-support,of this invention comprises a solid oxide of relatively high porosity, which exhibits Lewis acidic or Bransted acidic behavior. The solid o:dde is chemically-treated with an electron-withdrawing component, typically an electron-withdrawing anion or an electron-withdrawing anion source, to form a activator-support. Vftiile not intending to be bound by the following statement, it is believed that treatment of the inorganic oxide with an electron-Withdrawing component augments or enhances the a;idiry of the oxide. Thus, the activatorrsupppri exhibits Lewis or Bronsted acidity, which is topically greater than die Lewis' or Bnansted. acidity of-the untreated solid oxide. One method to quantify the acidity of the chemically-treated and untreated solid oxide materials is by
comparing the polymerization activities of the treated and untreated oxides under acid
i •
catalyzed reactions. Generally, it is observed that the greater the electron-withdrawing ability
or Lewis acidity of the activator-support, the greater its polymerization activity.
In one aspect, the chemically-treated, solid oxide comprises a solid inorganic oxide comprising oxygen and at least one element selected from Group 2, 3, 4, 5, 6, 7, 8, 9,10, 11, :.2,13, 14, or 15 of the periodic table, or comprising oxygen and at least one element selected Jrorn the lanthanide or actinide elements. (See:- Hawley's Condensed Chemical Dictionary, [1th Ed., John Wiley & Sons; '1995; Cotton," F.A.; Wilkinson, G.; Murillo; C. A.; and :3ochmann; M. Advanced-Inorganic Chemistry, 6* Ed.; Wiley-biterscience, 1999.) Usually, :he inorganic oxide comprises oxygen arid at least one element selected from Al, B, Be, Bi, Cd, Co, Cr, Cu, Fe, Ga, La, Mn. Mo. Ni, Sb". Si, Sn, Sr, Th, Ti, V, W, P, Y, Zn or Zr.
Suitable examples of solid, oxide materials or compounds that can be used in the chemically-treated solid oxide of the. present, invention include, but are not limited to,
B:;03, BeO, Bi2O3) CdO, Co304, Cr2O3, CuO, Fe2O3> Ga2O3> La2O3, Mn2O3) Mo03> NiO, P205j Sb205, SiO2, SnO2) SrO, ThO2, TiO^ V2O5, W03, Y2O3, ZnO, ZrO2, and the like, iniluding mixed oxides thereof, and combinations thereof. Examples of mixed oxides that can be used in the activator-support of the present invention include, but are not limited to, silica-alumina, silica-titania, silica-zirconia, zeolites, many clay minerals, alumina-titania, ahmina-zirconia, and the like.
In one aspect of this invention, the solid oxide, material is chemically-treated by contacting it with at least one electron-withdrawing anion, which may be derived from any electron-withdrawing component or.an.electrpnrwithdrawing anion source. Further, the solid oxide material is optionally chemically-treitdd with a metal ion, then calcining to form a metal-containing or metal-impregnated chemically-treated solid oxide. Alternatively, a solid oxide material and an electron-withdrawing anion source are contacted and calcined simultaneously. The method by which the oxide is contacted with an electron-withdrawing component, typically a salt or an acid of. an electron-withdrawing anion, includes, but is not limited to, gelling, co-gelling, .impregnation: of one -compound onto another, and the like. Typically, following any contacting method, the contacted mixture of oxide compound, electron-withdrawing anion,- and optionally the metal ion is calcined.
The electron-withdrawing component used to treat the oxide is any component that increases the Lewis or Br0nsted acidity of the solid oxide upon treatment. In one aspect, the e'.ectron-withdrawing component is an electrpn-withdrawmg anion source compound derived from a salt, an acid, or other compound such as a volatile organic compound that may serve as a source or precursor for that anion. Examples of electron-withdrawing anions and electron-withdrawing anion sources include, but are not limited to, sulfate, bisulfate, fluoride, chloride, bromide, iodide, fluorosulfate, fluoroborate, phosphate, fluorophosphate, tiifluoroacetate, Inflate, fiuorozirconate, fjuorotitanate, trifluoroacetate, triflate, and the like, including mixtures and combinations? therefcifl . In., addition, other ionic or non-ionic compounds that serve as sources for .these electron-withdrawing anions may also be employed in the present invention.
When the electron-withdrawing component comprises a salt of an electron-v/ithdrawing anion, the counterfoil or cation of that salt may be any cation that allows the salt to revert or decompose back, to-the acid during-calcining. Factors that dictate the suitability of the particular salt to serve as a source for the electron-withdrawing anion include, but are
net limited to, the solubility of the salt in the desired solvent, the lack of adverse reactivity of the cation, ion-pairing effects between the cation and anion, hygroscopic properties imparted to the salt by the cation, and the like, and thermal stability of the anion. Examples of suitable cations in the salt of the electron-withdrawing anion include, but are not limited to, ammonium, trialkyl ammonium, tetraalkyl ammonium, tetraalkyl phosphonium, H+, [K(OEt2)2]+, and the like.
Further, combinations of one or more different electron withdrawing anions, in varying proportions, can be used to'tailor fhe. specific acidity of the activator-support to the desired level. Combinations of electron withdrawing components may be contacted with the oxide material simultaneously or individually, and any order that affords the desired activator-support acidity. For example, one aspect of this invention is employing two or more electron-withdrawing anion source compounds in two or more separate contacting steps. Thus, one example of such a process by. which an activator-support is prepared is as follows: a selected solid oxide compound, or combination of oxide compounds, is contacted with a first electron-withdrawing anion source compound to form a first mixture, this first mixture is then calcined, the calcined first mixture is then contacted with a second electron-withdrawing anion source compound to form a second mixture, followed by calcining said second mixture to form a treated solid oxide compound. In such a process, the first and second electron-withdrawing anion source,compounds are typically different compounds, although they may be the same compound
In one aspect of the invention, the solid oxide activator-support is produced by a process comprising:
1) contacting a solid oxide compound with at least one electron-withdrawing anion
source compound to form a first mixture; .and'; : ;
2) calcining the first mixture to form the solid oxide activator-support.
In another aspect of this invention; the solid oxide activator-support is produced by a process comprising:
1) contacting at least one solid .oxide compound with a first electron-withdrawing
anion source compound to form a. first mixture; and
2) calcining the first mixture to produce a calcined first mixture;
3) contacting the calcined first mixture with a second electron-withdrawing anion
source compound to form a second mixture; and .
4) calcining the second mixture to iqrm the solid oxide activator-support Thus, the
solid oxide activator-support is sometimes referred to simply as a treated solid oxide or a
chemically-treated solid oxide.
Another aspect of this invention producing or forming the solid oxide activator-
. support by contacting at least one solid oii'de with at least one electron-withdrawing anion
source compound, wherein the at least one'.iSblid oxide compound is calcined before, during
or after contacting the electron-withdrawing anion source, and wherein there is a substantial
absence of aluminoxanes and organoboron compounds.
In one aspect of this invention, once the solid oxide has been treated and dried, it may
b ambient atmosphere, typically in a dry ambient atmosphere, at. a temperature from 200°C to
9()0°C, and for a time of 1 minute to 100 hours. In another aspect, calcining is conducted at a
temperature from 300°C to 800°C and .in. another aspect, calcining is conducted at a
temperature from 400°C to 700°C. In yet'another aspect, calcining is conducted from 1 hour
to 50 hours, and in another aspect calcining is conducted, from 3 hours to 20 hours. In still
another aspect, calcining may be carried out; from 1 to 10 hours at a temperature from 350°C
to 550°C. . . . ;•
Further, any type of suitable ambient can be used during calcining. Generally,
cdcining is conducted in an oxidizing .atmosphere, such as air. Alternatively, an inert
atmosphere, such as nitrogen or argon, or a reducing atmosphere such as hydrogen or carbon
monoxide, may be used. .
In another aspect of the invention,'the solid oxide component used to prepare the chemically-treated solid oxide has a pore volume greater than 0.01 cc/g. In another aspect, the solid oxide component has a pore volume greater than 0.1 cc/g, and in yet-another aspect, greater than 1.0 cc/g. In still another aspect,-the solid oxide component has a surface area
from 1 to 1000 m /g. In another aspect, sqlid-JQxide component has a surface area from -100 to 800 m /g, and in still another aspect, from 250 to 600 m /g.
The solid oxide material may be treated with a source of halide ion or sulfate ion, or a combination of anions, and optionally treated :with a metal ion, then calcined to provide the activator-support in the form of a particul'ate solid. In one aspect, the solid oxide material is treated with a source of sulfate, termed a-sulfating agent, a source of chloride ion, termed a chloriding agent, a source of fluoride ion, termed a fluoriding agent, or a combination thereof, and calcined to provide the solid oxide activator. In another aspect, useful acidic activator-supports include, but are not limited to:, bromided alumina; chlorided alumina; fluorided alumina; sulfated alumina; bisulfate-treated alumina; bromided silica-alumina, chlorided silica-alumina; fluorided silica-alumina;, sulfated silica-alumina; bromided silica-zirconia, ;hlorided silica-zirconia; fluorided silica-zirconia; fluorided silica-titania; fluorided-chlorided alumina; sulfated silica-zirconia; chlorided zinc aluminate; chlorided tungsten aluminate; fluorided silica-boria; silica treated with fluoroborate; a pillared clay such as a pillared montmorillonite, optionally treated with fluoride, chloride, or sulfate; phosphated alumina, or other aluminophosphates,- optionally treated with sulfate, fluoride, or chloride; or any combination thereof. Further, any of the activator-supports may optionally be treated with a metal ion.
In one aspect-of this invention, the treated oxide activator-support comprises, a. fluorided solid oxide in the form of a particulate solid, thus a source of fluoride ion is added to the oxide by treatment with a fluoriding" agent. In still another aspect, fluoride ion may be added to the oxide by forming a slurry of the oxide in a suitable solvent such as alcohol or water, including, but are not limited to, the one-to three carbon alcohols because of their volatility and low surface tension. Examples of fluoriding agents that can, be used in this invention include, but are not limited to, hydrofluoric acid (HF), ammonium fluoride (NHiF), ammonium bifluoride (NIl^HFa), amrhoriiurn -tetrafluoroborate (NH^F/t), ammonium silicofluoride (hexafluorosilicate) ((NH^SiFs), ammonium hexafluorophosphate analogs thereof, and combinations thereof. For example, ammonium bifluoride be used as the fluoriding agent, due to its ease of use and ready availability.
In another aspect of the present invention, the solid oxide can be treated with a fluoriding agent during the calcining ste|>:-'.'...Any fluoriding agent capable of thoroughly contacting the solid oxide during the calcining step can be used. For example, in addition to those fluoriding agents described previouslVj volatile organic fluoriding agents may be used. Examples of volatile organic fluoriding agents useful in this aspect of the invention include,

but are not limited to; freqns, perfluorohexane, perfluorobenzene, fluoromethane, trifluoroethanol, and combinations thereof. Gaseous hydrogen fluoride or fluorine itself can also be used with the solid oxide is fluorided dining Calcining. One convenient method of contacting the solid oxide with the fluonding agent is to vaporize a fmoriding agent into a gas stream used to fluidize Die solid oxide during calcination.
Similarly, in another aspect of this invention, the chemically-treated solid oxide comprises a chlorided solid oxide in the farm of a particulate solid, thus a source of chloride ion is added to the oxide by treatment with a chloriding agent. The chloride ion may be added to the oxide by forming a slurry of the oxide in a suitable solvent. In another aspect of the present invention, the solid oxide can be treated with a chloriding agent during the calcining step. Any chloriding agent capable of serving as a source of chloride and thoroughly contacting the oxide during the calcining step can be used. For example, volatile organic choriding agents may be used. Examples of volatile organic choriding agents useful in this aspect of the invention include, but are not limited to, certain freons, perchlorobenzene, cMoromethane, dichloromethane, chloroform, caibon tetrachloride, trichtoroethanol, or any combination thereof. .Gaseous hydrogen chloride or chlorine itself can also be used with the solid oxide during calcining. One convenient method of contacting the oxide with the ehloriding agent is to vaporize a chloriding agent iittb a gas stream used to fluidize the solid oxide during calculation.
In one aspect, the amount of fluoride or chloride ion present before calcining the solid oxide is .generally from 2 to 50% by weight, where the weight percents are based on the weight of the solid oxide, for example silica-ahimma, before calcining, hi another aspect, the amount of fluoride or chloride ion present before calcining the solid oxide is from 3 to 25% by weights and in another aspect, from 4 to 20.% by weight If the fluoride or chloride ion are added during calcining, such as when calcined in the presence of CCU, there is typically no fluoride, or chloride ion in the solid oxide befote calcining. Once impregnated with halide, the halided oxide may be dried by any method known in the art including, but not limited to, suction filtration followed by evaporation, drying tinder vacuum, spray drying, and the like, although it is also possible to initiate the calcining step immediately without drying the impregnated solid oxide.
The silica-alumina used to prepare (he treated silica-Alumina can have a pore volume greater than 0.5 cc/g. In one aspect, the ppxe volume may be greater flian 0.8 cc/g, and in
another aspect, the pore volume may be greater than l.Q cc/g. Further, the silica-alumina may have a surface area greater than 100 ml/g. La one aspect, the surface area is greater than 25.0 mz/g, and in another aspect, the surface area may be greater than 350 m2/g. Generally, the silica-alumina of this invention has an alumina content from 5 to 95%. In one aspect, the alumina content of the silica-alumina may be from 5 to 50%, and in another aspect, the alumina content of the silica-alumina may be from 8% to 30% alumina by weight.
The sulfated solid oxide comprises' sulfate and a solid oxide component such as alumina or silica-alumina, in the form of a particulate solid. Optionally, the sulfated oxide is further treated with a metal ion such that the calcined sulfated oxide comprises a metal, tn
, ».
one aspect, the sulfated solid oxide comprises sulfate and alumina, la one aspect of this invention, the sulfated alumina is formed by a process wherein the alumina is treated with a sulfate source, for example ,. but not limited to, sulfuric acid or a sulfate salt such as ammonium sulfate. In one aspect, this process may be performed by forming a slurry of the aiumina in a suitable solvent such as alcohol or water, in which the desired concentration of the sul&nng agent has been added. Suitable organic solvents include, but are not limited to, the one to three carbon alcohols because of their volatility and low surface tension.
The amount of sulfate ion present before calcining is generally from 1 to 50 % by weight, typically from 5 to 30 % by weight, and more typically from 10 to 25% by weight, where the weight percents are based on the weight of the solid oxide before calcining. Once impregnated with sulfate, the sulfated oxide may be dried by any method known in the art including, but not limited to, suction filtration followed by evaporation, drying under vacuum, spray drying, and the like, although it is also possible to initiate the calcining step immediately.
In addition to being treated with an electron-withdrawing component such as halide or sulfate ion, the solid inorganic oxide of this invention may optionally be treated with a metal source, including metal salts or metal-wjmaining compounds. In one aspect of the invention, these compounds may be added to or impregnated onto the solid oxide in solution form, and subsequently converted into the supported metal upon calcining. Accordingly, the solid inorganic oxide can further comprise a metal selected from zinc, nickel, vanadium, silver, copper, gallium, tin, tungsten, molybdenum, or a combination thereof. For example, zinc may be used to impregnate the solid oxide because it provides good catalyst activity Snd low
cost. The solid oxide may be treated wife metal salts or metal-containing compounds before, after, or at the same lime that the solid oxide is treated with the electron-withdrawing anion.
Farther, any method of impregnating the solid oxide material with a metal may be used. The method by which the oxide is contacted with a metal source, typically a salt or metal-containing compound, includes, but is not limited to, gelling, co-gelling, impregnation of one compound onto another, and the like. Following any contacting method, the contacted mixture of oxide compound, electron-withdrawing anion, and die metal ion Is typically calcined. Alternatively, a solid oxide material,, an electron-withdrawing arrion source, and the metal salt or metal-containing compound are contacted and calcined simultaneously.
In another aspect, the metallocene compound may be contacted with an otefin monomer and an organoalummum cocatalyst for a first period of time prior to contacting this mixture with the acidic activator-support. Once the precontacted mixture of metallocene, monomer, organoaluminum cocatalyst is contacted with the acidic activator-support, the composition further comprising the acidic activator-support is termed the "postcontacted" mixture. The postcontacted mixture may be allowed to remain in farther contact for a second period qf nine prior to being charged into the. reactor in which the polymerization process wi]] be carried out
Various processes to prepare solid oxide activator-supports that can be employed in mis invention have been reported. For example, U.S. Patent Nos. 6,107,230, 6,165,929, 6,294,494,6,300,271,6,316,553, 6,355,594, 6,376,415, 6,391,816,6,395,666,6,524,987, and 6,548,441, describe such methods, each of which is incorporated by reference herein, m its entirety.
The Optional Alwrdnoxane Cocatalyst
In one aspect, the present invention provides a catalyst composition comprising at least one metallocene, at least one organoalumimun compound, at least one olefinic or acetylenic monomer, and at least one acidic activator-support; and farther comprising an optional cocatalyst. In one aspect, me optional cocatalyst may be at least one aluminoxane, at least one organoboron compound, at least one ionizing ionic compound, or any combination thereof. In another aspect, the optional cocatalyst may be used in the
precontacting step, in Die posteontacting step, or in both steps. Farther, any combination of cocatalysts may be used in either step, or in both steps.
Alumraoxanes are also referred to as poly(hydrocarbyl aluminum oxides) or simply organaaluminoxanes. The other catalyst components are typically contacted with the aluminoxane in a saturated hydrocarbon compound solvent, though any solvent that is substantially inert to the reactants, intermediates, and products of the activation step can be used. The catalyst composition formed in this manner may be collected by methods known to those of still in the art, including but not limited to filtration, or die catalyst composition may be introduced into the polymerization reactor without being isolated.
The aluminoxane compound of this invention is an oligomeric aluminum compound, wherein the aluminoxane compound can comprise linear structures, cyclic, or cage structure!;, or typically mixtures of all three. Cyclic aluminoxane compounds having the formula:
R ; wherein
R is a linear or branched alkyl having from 1 to 10 carbon atoms, and n is an integer from 3 to 10 are encompassed by this invention. The (A1RO),, moiety shown here also constitutes me repeating unit in a linear aluminoxane. Thus, linear aluminoxanes having die formula:
R
:-(-Ai-o4-AJ \ I /n
; wherein:
R is a linear or branched alkyl having from 1 to 10 carbon atoms, and n is an integer from 1 to 50, are also encompassed by mis invention;.
Further, aluminoxanes may also have cage structures of the formula
wherein m is 3 or 4 and a is "-HAI^) --«oc3) + Xb(4)', wherein HAIO) is the number of three coordinate aluminum atoms,, itocz) is the number of two coordinate oxygen atoms, HOW is the number of 4 coordinate oxygen atoms, R' represents a terminal alkyl group, and Rb represents a bridging alkyl group; wherein R is a linear or branched alkyl having from 1 to 10 carbon atoms.
Thus, aluminoxanes that can serve as optional cocatalysts in this invention are generally represented by formulas such as (R-Al-Q)* R(R-Al-O)BAlRz, and the like, wherein the R group is typically a linear or branched Ct-Ce. alkyl such as methyl, ethyl, propyl, butyl, pentyl, or hexyl wherein n typically represents an integer from 1 to 50. In one embodiment, the aluminoxane compounds of this invention include, but are not limited to, methylalummoxane, ethylahimmoxane, n-propylalummoxane, iso-propyl-aluminoxane, n-butylaluminoxane, t-butyl-aluminoxane, sec-butylalurninoxane, iso-butylalumlnoxane, 1-pentyl-aluminoxane, 2-pentylaluminoxanc, 3-pentyl-aluminoxanc, iso-pentyl-aluminoxane, neopentylaluminoxane, or combinations thereof.
While organoaluminoxanes with different types of R groups are encompassed by the present invention, methyl ahuninoxane (MAO), ethyl ahuninoxane, or isobutyl aluminoxane are typical optional cocatalysts used in the catalyst compositions of this invention. These aluminoxanes are prepared from . trimefhylalummum, trietbylalummum, 01 triisobutylaluminum, respectively, and are sometimes referred to as poly(methyl aluminum oxide), poly(ethyl aluminum oxide), and poly(ispbutyl aluminum oxide), respectively. It is also within the scope of the invention to use an aluminoxane in combination with a trialkylaluminum, such as disclosed in U.S. Patent No, 4,794,096, which is herein incorporated by reference hi its entirety.
The present invention contemplates many values of n in the aluminoxane formulas (R-A1-O)0 and R(R-Al-O)nAlR2. and preferably n is at least 3. However, depending upon how the organoaluminoxane is prepared, stored, and used, the value of n may be variable within a single sample of aluminoxane, and such a combination of organoaluminoxanes are comprised in the methods and compositions of the present invention.
In preparing the catalyst composition of this invention comprising an optional aluminoxane, the molar ratio of the aluminum in the alumixoane to the metallocene in the composition is usually from 1:10 to 100,000:1. In one anomer aspect, the molar ratio of the aluminum in the alumixoane to die metallocene- hi the composition is usually from 5:1 to 15,000:1. The amount of optional aluminoxane.added to a polymerization zone is an amount wimin a range of 0.01 mg/L to 1000 mg/L, from 0.1 mgyL to 100 mg/L, or from I mg/L to abutSflmg/L.
Organoaluminoxanes can be prepared by various procedures which are well known in the art. Examples of prganoaluminoxane preparations ate disclosed in U.S. Patent Nos. 3,242,099 and 4,808,561, each of which is incorporated by reference herein, in its entirety. One example of how an akminoxane may be prepared is as follows. Water that is dissolved in an inert organic solvent can be reacted with an aluminum alkyl compound such as AIR; to form the desired organdaluininoxane compound, While aot intending to be bound by this statement, it is believed that this synthetic method can afford a mixture of both linear and cyclic (R~Al-O)n aluminoxane species, both of which ate encompassed by this invention. Alternatively, organoaluminoxanes may be prepared by reacting an aluminum alkyl compound such as AIRs with a hydrated salt, such as hydrated copper sulikte, in an inert organic solvent.
The. Optional Organoboron Cpcatalyst
In one aspect, the present invention provides a catalyst composition comprising at least one metallocene, at least one organoalumhtum compound, at least one olefinic or acetylenic monomer, and at least one acidic activator-support, and further comprising an optional cocatalyst In one aspect, the optional cocatalyst may be at least one aluminoxane, at least one organoboron compound, at least one ionizing ionic compound, or any combination thereof, Ifi another aspect;- the optional cocatalyst may be used in the precontacting step, in the postcontacting step, or in bom steps. Further, any combination of cocatalysts may be used in either, step, or ifi both stops.
In one aspect, the organoboron compound comprises neutral boron compounds* berate salts, or combinations thereof. For example,, the organoboron compounds of this invention can comprise a fluoroorgano boron compound, a fluojoorgaBO borate compound, or a combination thereof. Any fluoroorgano boron or fluoroorgano borate compound known in the art can be utilized. The term fluoroorgano boron compounds has its usual meaning to refer to neutral compounds of the form BYj. The term fluoroorgano borate compound also has its usual meaning to refer to the monoanipm'c salts of a ftuoroorgano boron compound of the form [cation]* [BY4l~, where Y represents a fluorinated organic group. For convenience, fluoroorgano boron and fluoroorgano borate compounds are typically referred to collectively by organoboron compounds, or by either name as the context requires.
Examples of fluoroorgano boiate compounds that can be used as cocatalysts in the present invention include, but are not limited to, fiuormated aryl borates such as, N,N-
dimethylanilinium tetrakis-(pentafluorpphenyl>1jorate, triphenylcaibenium
tetrakisfpentafluoropheny^borate, lithium tetrakis-(pentafluorophenyl)borate, ff,N-dimethylanib'ntum tetrakis[3,5-bis(trifluoro-niefliyl)phenyl]boratej triphenylcarbenium tetrakis[3,5-bis(trifluordmethyl)-phenyl]borate, and the like, including mixtures thereof. Examples of fluoroorgano boron compounds that can be used as cocatalysts in the present invention include, but are not limited to, tris(pentafluoropheny])boron, tris[3,5-bis(triflaorornethyl>rpbenyl]boron> and the like, including mixtures thereof.
Although not intending to be bound by the following theory, these examples of fluorborgano borate and fhioroorgano boron compounds, and related compounds, are thought to form "weakly-coordinating" anions when combined with organometal compounds, as disclosed in U.S. Patent 5,919,983, which is incorporated herein by reference in its entirety.
Generally, any amount of organoboron compound can be utilized in this invention. In one aspect, the molar ratio of the organoboron compound to the metallocene compound in the composition is from 0.1:1 to 10:1. Typically, the amount of the fluoroorgano boron or fluoroorgano borate compound used as a cocatalyst for the metallocene is in a range of from 0.5 mole to 10 moles of boron compound per mole of metaUocene compound. In one aspect, the amount of fluoroorgano boron or fluoroorgano borate compound used as a cocatalyst for the metallocene is in a range of from 0.8 mole to 5 moles of boron compound per mole of metallocene compound.
The Optional Ionizing Ionic Compound Cocatalyst
In one aspect, the present invention-provides a catalyst composition comprising at least one metallocene, at least one organoaluminuro compound, at least one olefinic or acetylenic monomer, and at least one acidic activator-support, and further comprising an optional cocatalyst In one aspect, the optional cocatalyst may be at least one aluminoxane, at least one organoboron compound, at least one ionizing ionic compound, or any combination, thereof. In another aspect^ the optional .cocatalyst may be used hi the precontacting step, hi the postcontacting step,.or in both steps. Further, any combination of cocatalysts may be used in either step,, or in both steps. Examples of ionizing ionic compound are disclosed in U.S. Patent Numbers 5,576,259 and 5*807,938, each of which is incorporated herein by reference, in its entirety.

An ionizing ionic compound is an ionic compound which can function to enhanos activity of the catalyst composition. While not bound by theory, it is believed that the ionizing ionic compound may be capable of reacting with the metalldcenc compound and converting the metallocene into a cationic metallpcene compound. Again, while not intending to be bound by theory, it is believed-that the ipnizjng ionic compound may function as an ionizing compound by completely or partially extracting an anionic ligand, possibly a non-ii 5-alkadienyl Hgand sufch as (X3) or (X*), fitom the metallpeene. However, the ionizing ionic compound is an activator regardless of whether it is ionizes the metallocene, abstracts an (X3) or (X4) ligand in a fashion as to form an ion pair, weakens the metal-(X3) or metal-(X4) bond in the metallocene, simply coordinates to an (X3) or (X4) ligand, or any other mechanisms by which activation may occur: Further, it is not necessary that the ionizing ionic compound activate the: metallocene only. The activation function of the ionizing ionic compound is evident in the enhanced activity of catalyst composition as a whole, us compared to a catalyst composition contaiaing catalyst composition that does not comprise any ionizing ionic compound.
Examples of ionizing ionic compounds include, but are not limited to, the following compounds: tri{n-butyl)ammonium tetrakis(p-tolyl)borate, tri(n-butyl)ammonium tetrakis(ni-tolyl)borate, tri(n-butyl)ammonium tetrakis(2,4-dimelliyl)borate, tri(n-butyl)ammoniuin tetxakis(3,5-dimethylphenyl)bqrate, tn(n-butyl)ammonium tetrakis[3,5-bis(trifluon)-memyl)phenyl]borate, tri(n-butyl)arnmoruum tetrakis(pentafluorophenyl)borate, N,N-dimemylanilinium tetrakis(p-tolyl^iorate, N^I-dimetbylanilinium tetrakis(m-tolyl)borati5, N^-dhnethylaniliniurh tctrakis(2,4-diaiethylphenyl)borate, N,N-dimethylaniumuin tetrakis(S,5-dimethyl-phenyl)borate, N,N-dunethyhmilinium tetrakis[3,5-bis(trifluoro-methyl)phenyl]borate, N,N--dimethylphenyl)borate, triphenylcarbenimn «rakist315-his(trifluoro-methyl)phenyl]borat5, triphenylcarbenium tetrakis{pentafluoTOphenyI)borate, tropylium tetrakis(p-tolyl)borate, tropylium tetrakis(m-tolyl)borate, tropylium tetrakis(2,4-clirnethylphenyl)borate, tropylium tetrakis(3I5-dimethylphenyl)borHte, tropylhim tetrakis[3i5-bis(trifluoTo-methyI)phenyl]borate, tropylium tetraki8(pentafluorophenyl)boratej limium tetrakis(perrtafluorophenyl)-boratt5, lithium tetrakis(phenyl)borate, lithium tetrakiB(p-lolyl)borate, lithium tetrakis(ro-tolyl)boTati5, littihim tetrakis(2,4-dimel:hylphenyl)borate, -lithiura tetrakis-(3,5-dimethylphenyl)borat;,
lithium tetrafluoroborate, sodium tetrakis{pentajauoro-pbenyl)boiate, sodium tetrakis(phenyl)
borate, sodium tetrakis{p-tolyl)borate, sodium tetrakis(m-tolyl)borate, sodium tetrakis(2,4-
dimethylphenyljborate, sodium tetrakis-{3,5-dnneAylphenyl)boiateJ sodium
tetrafluoroborate, potassium tetrgkis-(pentafluorDplienyl)borate, potassium
tetralds(phenyl)borate, potassium teuakis potassium tetrakis(2i4-dimeUiyl-plxenyl)borate, potassium tetrakis(3,5 •
dimethylphenyl)borate, potassium tetrafluoro-bdrate, tri(ti-butyl)ammonium tetrakis(p-
tolyl)alumraate, tri(n-butyl)animonium tettakis(m-totyl)aluinmate, tri(n-butyl)ammotriuiri
tetrakis(2,4-dimethy])aluminate, tri(n-butyl)ammoirium tetrakis(3,5-dimethylpheny[;!
aluminate, tri(n-butyl)aininonium . tettakis(peritafluorophenyl)aluminate, N,N-
dhnefliylanilinium tetrakis(p-tolyl)-aluminate, N^J-dimefliylaiiilinium tetralds(m-
tolyl)aluminate, N,N-dimethylamliniuia tetrakis(2)4-dittjefliylphenyl)aluminate, N,N-
dimethylaniliniunj tctraki^S.S-dimetiiyl-pheny^alumiiiate, N^N-dimethylanilinium tetrakis
(pentafluQropheny])alummate, tripheiiylparbenium tetrakis(p-tolyl)aluminate,
triphenylcarbenium tetrakjs(m-folyl)-alununate, triphenylcarbenium tetrakis(2,4-dimethylphenyl)alunoinate, triphenyl-carbenium tetrakis(3,5-dimediy]phenyl)aluminate, tripbenylcarbenium tetrakis-(peQtafluprDphenyl)alummate> trgpylium tetrakis(p-tolyl)aluminate, tropylium tetrakis(m-tolyL}aluminate, ttopylium tetrakis(2,4-dimethylphenyl)aluminate, tropylium tetrakis(3,5-dunethylphenyl)aluminate, tropylium tetrakis(pentafluoro-phenyl)aluminate, limium tetrakis(pentafluorophenyl)aluminate, lithium tetrakis-(phenyl)aluniinate, lithium tetraki8(p-tolyl)alurainate, u'thium tetrakis(m-tolyl)a]uminate, limium tetrakis(2,4-diinetiiylphenyl)aluminate, lifliium tetrakis(3,S-dimethylphenyl)aluminate, limium tetrafluoraaluminate, sodium tetrakis(pehtafluoro-phenyl)aluminate, sodium tetrakis(phenyl)alummate, sodium tetrakis(p-tolyl)-aluniinate)
i
sodium tetrakis(m-tolyl)aluminate, sodium tetrakiis(2,4-dimetiiylphenyl)-alumuiate, sodium tctrakis(3,5-dimcthylpheHyl)alummatB, sodium tetrafluoro-ahiminate, potassium tetrakisfrentafluorophenyljaluminate, potassium tetiakis-(phenyl)alummate, potassium tetrakis(p-tolyl)a!uminatc, potassium tetrakis(m-tolyl)-aLuminate, potassium tetrakis(2,4-dimethylphenyl)aluminate, potassium tetrakis (3,5-dimethytphenyl)aluminate, and potassium tetrafluoroalurainate. However, the ionizing ionic compound is not limited thereto in the
Preparation of the Catalyst Composition
In accordance with this invention, the catalyst compositions may be prepared by a process comprising precontacting an organoaluminum cocatalyst compound with an olefra or alkyne and an organometal compound for an effective period of time, before this mixture is contacted with the activator-support for ah effective period of time. In one aspect, the process of preparing the catalyst of this invention may occur in an inert atmosphere and under substantially anhydrous conditions. Thus, the atmosphere is substantially oxygen-free and substantially free of water as the reaction begins, to prevent deactrvation of the catalyst. In one aspect of this invention, for example, 1-hexene, triethykluminurn, and a zirconium metaUocene, such as fcw(mdenyl)zirconium dichloride or feis(cyc!opentadienyl)-zirconium dichloride are precontacted for at least 30 minutes prior to contacting this mixture with a fluorided silica-alumina activator-support Once this precontacted mixture is brought into contact with the activator-support, this postcontacted mixture is allowed to remain in contact for trom 1 minute to 24 hours, typically from 5-minutes to 5 hours, and more typically from 10 minutes to 1 hour, prior to using this mixture in a polymerization process.
Typically, the mixture of metaUocene, olefin or alkyne monomer, and organoaluminum compound, before it is contacted with the activator-support, is termed the "precontacted" mixture. Accordingly, the components of the precontacted mixture are termed precontacted metallocene, ptecontaeted.olefin or alkyne monomer, and precontacted organoaluminum compound. The mixture of the precontacted mixture and the acidic activator-support, that is, the mixture of the metallocene, olefin or alkyne monomer, organoaluminum compound, aad acidic activator-support, is typically termed the "postcontacted" mixture. Accordingly, the components of the postcontaeted mixture are termed postcontacted metallocene, postcontaeted olefin or alkyne monomer, postcontacted organoaluminum compound, and postcontacted acidic activator-support.
In one aspect of this invention, improved catalytic-activities may be achieved when the precontacted mixture comprises various components other man the metallocene, olefin or alkyne monomer, and organoaluminum compound In this aspect, the components of the precontacted mixture and the. postcontacted mixture vary, such that the resulting catalyst composition can be tailored for the desired- activity, or to accommodate a particular polymerization process.
The precontacting step may be carried out in a variety of ways, including but not limited to, blending. Furthermore, each of the organometal, monomer, and organoaluminum
cocatalyst compounds can be fed into a reactor separately, or various combinations of these compounds can be contacted with each other before being farther contacted in the reactor. Alternatively, all three compounds can be contacted together before being introduced into the reactor. Typically, the mixture of metallocene, alkene or alkyne, and organoaluminum compound was precontacted from minutes to days in a separate reactor, prior to contacting this mixture with activator-support to form the postcontacted mixture. This precontacting step is usually carried out under an inert atmosphere. Further, the precontacting step may be carried out with stirring, agitation, heating, cooling, sotiican'on, shaking, under pressure, at room temperature, in an inert solvent (typically a hydrocarbon), and the like. However, such conditions are not necessary as the precontacting step may be carried out by simply allowing the components to stand substantially undisturbed.
In another aspect of this invention, the precontacted mixture is prepared first by contacting an organoaluminum compound, an olefin or acetylene, and an organometa] (typically a metallocene) compound before injection into the reactor, typically for 1 minute tc 9 days, more typically from 1 minute to 24 hours. The components of the precontacted mixture are generally contacted at a temperature from 10°C to 200°C, typically from 15°C to 80°C. This precontacted mixture is then placed in contact with the acidic activator-support, typically a fluorided silica-alumina activator-support as disclosed herein, to form the postcontacted mixture.
The postcontacted mixture is prepared by contacting and admixing the acidic activator-support and the precontacted mixture for any length of time and at any temperature and pressure that allows complete contact and reaction between the components of the postcontacted mixture. For example, this postcontacted mixture is usually allowed to remain in contact for from 1 minute to 24 hours, typically from 5 minutes to 5 hours, and more typically from 10 minutes to 1 hour, prior to using this mixture in a polymerization process. Once the acidic activator-support and the precontacted mixture have been in contact for a period of time, the composition comprises a post-contacted organometal compound .(typically, a metallocene), a postcontacted organoaluminum compound, a postcontacted olefin or alkyne, and a postcontacted acidic, activator-support (typically fluorided silica-alumina). Generally, the postcontacted acidic activator-support is the majority, by weight, of the composition. Often, the specific nature of the final components of a catalyst prepared as described herein are not known, therefore the catalyst composition of the present invention is
described as comprising ppstcontaoted compounds and components. Further, because the exact order of contacting can be varied* it is believed that this terminology is best to describe the composition's components.
In one aspect, the postcontacting step in which the precontacted mixture is placed in contact with the acidic activator-support is typically carried out in an inert atmosphere. Contact times between the acidic activator-support and die precontacted mixture typically range from time O.I hour to 24 hours, and from 0.1 to 1 hours is more typical. The mixture may be heated to a temperature from between 0°F (-17.7 °C) to 150°F (65.56 °C). Temperatures between 40°F (4.44 9C) to 95°F (35 °C) are typical if the mixture is heated at all. While not intending to be bound by theory, these conditions are thought to assist in the deposition of a catalytically-effective amount of the catalyst on the acidic activator-support.
In general, heating is carried out at a temperature and for a duration sufficient to allow adsorption, impregnation, or interaction of precontacted mixture and the acidic activator-support, such that a portion of the components of the precontacted mixture is immobilized, adsorbed, or deposited thereon. For example, in one aspect, a catalyst composition of this invention is prepared by contacting ,1-hexene, triethylaluminum, and a zirconium metallocene, such as i>ts(indenyl)zirconium dichloride or 6u(cyclbpentadienyl)-zirconium dichloride for at least 30 minutes, followed by contacting this precontacted mixture with a fluorided silica-alumina activator-support for at least 10 minutes up to one hour to form the active catalyst.
More than one metalloeene can be .used in the catalyst composition and methods of the present invention. When a catalyst composition comprises more than one metalloeene, the metalloeene compounds are employed in one or more precontacted mixtures. Thus, these multiple metalloeenes may be employed in the same precontacted mixture and then used in the same posteontacted mixture, they can be employed in different precontacted mixtures which are then used to prepare the same posteontacted mixture, or they can be employed in different precontacted mixtures and different posteontacted mixtures which are then introduced into the polymerization reactor. • • '
In one aspect, the molar ratio of .the organometal or metalloeene compound to the organoaluminum compound is 1:1 to 1:10,000, typically from 1:1 to 1:1,000, and more typically from 1:1 to 1:100. These molar ratios reflect flic ratio
the total amount of organoaluminum compound in both the precontacted mixture and this postcontacted mixture.
Generally, the molar ratio of olefin or aQcyne monomer to organometal or metallocene compound in the precontacted mixture is 1:10 to 100,000:1, typically from 10:1 to 1,000:1.
In another aspect of this invention^.the weight ratio of the acidic activator-support tc the organoaluminom compound generally ranges from 1:5 to 1,000:1, typically from 1:3 tc 100:1, and more typically from 1:1 to 50:1, In a further aspect of mis invention, the weigh! ratio of the metallocene to the acidic activator-support is typically from 1:1 to 1:10,000,000. more typically from 1:10 to 1:100,000, even more typically from 1:20 to 1:1000. These ratios that involve the acidic activator-support are based on the amount of the components mat have been added to make up the postoontacted mixture to provide the catalyst composition.
One aspect of mis invention is that alumhioxane is not required to form the catalyst composition disclosed herein, & feature mat allows lower polymer production costs. Accordingly, the present invention uses only AlRj-type organoaluminum compounds which does not activate the metallocene catalyst in the same manner as an organoaluminoxane. Additionally, no expensive borate compounds or MgClj are required to form the catalyst composition of mis invention, although aluminoxane, borate compounds, MgCl2) or combinations thereof can optionally be used in some aspects of this invention. However, another aspect of mis invention is the use of optional cocatalysts, including, but not limited to, at least one aluminoxane, at least one organoboron compound, at least one ionizing ionic compound, or any combination thereof.
It is believed that the unexpected enhancements in the catalytic activity observed from precontacting certain catalyst components may be related to the formation of organoaluminum metallacycUc compounds, • based upon the reported synthesis of aluminacyclo-pentanes (ACPs) according to the following reaction scheme, Scheme 1, using (n^jHsfcZrCfe, AJEtj, and CH2=CHCHjR (R - CjH7, GjHn, or CgHn), where T15-C5H5 = Cp.

One reaction scheme to produce ACPs is .described in: U.M. Dzhemilev and A.G. Ibragimov, Journal ofOrganometaltic Chemistry, 1994, 466, 1-4, which, along with the references and citations referred to therein, each of which is incorporated by reference herein, in its entirety. Other reaction schemes to produce ACPs are described in Khalikov, L.M.; Parfenova, L. V.; Rusakov, S.V.; Ibragimov, A.G.; Dzhemilev,.U.. M. Russian Chemical Bulletin, International Addition 2000, 49, (12), 2051-2058. See also:* Negishi, E.; Kondafcov, Denis, Y.; Choueiry, D.; Kasai, KL; Takahashi, T. Journal of.the American Chemical Society 1996, 775, 9577-9588, each of which is incorporated by referenced herein, in its entirety. According to Scheme 1, when the organotnetal .(typically metallocene) compound and an organoaluminum compound are precontacted with an olefin, an aluminacyclopentane can form. While not intending to be bound by mis statement, according to ibis reaction scheme and analogous reactions schemes described in Dzjiemilev, U. M:; Ibragimov, A. G. Russian Chemical Reviews 2000, 69, (2) 121-135 when the organometal (typically mefaflocene) compound and an organoaluminum compound are precontacted with an alkyne, an aluminacyclopentene can form. A mixture of an olefin and an alkyne in the precontacted mixture would be expected to form an aluminacyclopentane and an atuminacyclopentene, in an analogous manner.
La accordance with KhaHkoV, L.M.; Parfenova, L. V.; Rusakov, S.V.; Ibragimov, A.G.; Dzhemilev, U. M. Russian Chemical Bulletin, International Addition 2000, 49, (12). 2051-2058, and the references: and citations referred to therein, mere are several possible mechanisms by which Scheme 1 can operate, one of which is presented in Scheme 2. Note mat only one regioisomer of intermediate B is shown, leading to the aluminacyclopentane (AGP) regioisomer C shown.


However, this scheme would also be expected to provide some of the a-substituted aluminacyclopentane, structure D, shown here:

(Figure Remove)
EtAi;
D .
Thus, for any particular compound disclosed herein, any general structure presented also encompasses all isomers, including all regioisomers that may arise from a particular set of substitutents or from a particular reaction scheme, as the context requires.
Another aspect of this invention is the catalyst composition comprising aluminacyctopentanes or metaliacyclopentane of a metalloeene, such as a zoconacyclopentanes. Thus, this-invention encompasses a catalyst composition comprising a precontacted metallocenej a precoatacted .olefin or alkyne, a postcontaeted acidic activator-support, and an aluminacyelopentane. This invention also encompasses a catalyst composition comprisiag a precontacted metalloeene, a precontacted olefin or alkyne, a postcontaeted acidic activator-support, and a metallacyclopehtane or a metallacyclopentene of a metalloeene.
Also, while not intending to be hound by theoretical statements, the reaction schemes above may also explain why triethyJahiminum -(TEA) worlds well to fonn the precontacted solution, while trimethylaluminom (TMA) does not. As indicated in Scheme 2, if the
aluminum alkyl compound used in the precontacted mixture contains jJ-hydrogen atoms, these alkyl groups can participate in the P-H elimination process shown when coordinated to the organometal compound, thereby forming the arcom'um-ahirninurn compound and ths resulting ztreonacyclopentane and ACP. Tlie ethyl groups of TEA have p-hydrogeri atoms while the methyl groups of TMA do not
While not intending to he bound by the theory, it is believed that different aluminacyclopentanes (ACPs) can arise when two olefihs are present in solution. For example, if both CHrCHCHjR and CHr=CH2 are present in solution, additional aluminacyclopentanes analogous to C and D are believed to be accessible in a precontacL solution that contained both CH2s=CHCHiR and CHjK^Hj (regardless of whether thti ethylene was introduced pr was derived front AIEts), which could also give rise to the following aluminacyclopentanes E-H, derived from homocoupling of the same two olefins at: a single metal site
As illustrated in Scheme 2, these various aluminacyclopentanes would arise from the analogous zirconacyclopentanes.
in another aspect, this invention encompasses a catalyst composition that comprises a precontacted metallocene, a precontacted olefin or alkyne, a postcontacted acidic activator-support, and an aluminacyelopentane. Thus, the catalyst composition of this invention can comprise an aluminacyelopentane (E, F, G, H) or an aluminacyclopentene (I), whether generated by the reaction schemes disclosed herein, or whether prepared independently. Similarly, this invention also encompasses a catalyst composition that comprises a precontacted metallocene, a precontacted olefin or alkyne, a postcontacted acidic activator-support, and a zirconacyclic species. As indicated in Scheme 2 and the references cited above, this cyclic organometal species can be a zirconacyclopentane (J) or a zirconacyclopentene (K) of any metalloeene used in this invention, whether generated by the
(Figure Remove)
The formation of an alumhiacyclopentane upon prccontacting a metallocene compound, an organoaluminum compound, and an olefin in the present invention WES monitofed by gas chromatograpby of the hydrolysis products of the aluminacyclopentane, tis
"".'"
well as by gas (ethane) evolution when TEA is employed as the an organoaluminum compound, Accordingly, one aspect of this invention comprises preparing .organoaluminum metallacyclic compounds, based upon the synthesis of aluminacyclopentanes reported in U.M. Ctehemilev and A.G. Ibragjmov, Journal ofOrganometallic Chemistry, 1994, 466,1-4, and using the reaction mixture comprising -the aluminacyclopentanes in place of the precontacted mixture, according to the present reaction,.
In another aspect of this invention, the components of the precontacted mixture and the postcontacted mixture vary, such that the resulting catalyst composition can be tailored for the desired activity, or the method of preparing the catalyst composition can accommodate the desired polymerization process. For example, in one aspect, the catalyst composition of this invention comprises a precontacted metallocene, a precontacted organoaluminum compound, a postcontacted olefin or alkyne, and a postcontacted acidic activator-support In another aspect, the catalyst composition of this invention comprises it precontacted metallocene, a posteontacted organoaluminum compound, a precontacted olefin or alkyne, and a postcontacted acidic activator-support. In a further aspect, the catalyst: composition of this invention comprises, a 'precontacted metallocene, a postcontacted organoaluminum compound, a precontacted olefin or alkyne, and a precontacted acidic activator-support lit yet another aspect, the catalyst composition of this invention comprises a precontacted metallocene, a precontaeted olefrri or alkyne, a postcontacted acidic activator* support, and an aluminacyclopentane or aluminacyclopentene. In each of these aspects in which the components of the precontacted or postcontacted mixtures vary, the relative amounts, of each component in the precantacfced or postcontacted mixtures are typically within the same ranges as those .disclosed, here for the catalyst composition comprising a precontacted metallocene, a precontacted organoalaminum compound, a precontacted olettn or alkyne, and a postcontacted acidic activator-support
Utility of the Catalyst Compositipn in Polymerization Processes
In one aspect, catalyst composition of this invention can have an activity greater than a catalyst composition mat uses the same components, but does not involve precontacting the organometal compound, the organoaluminum compound, and an olefin or alkyne monomer.
Polymerizations using the catalysts of this invention can be carried out in any manner known in the art Such polymerization .processes include, but are not limited to slurry polymerizations, gas phase polymerizations, solution polymerizations, and the like, including multi-reactor combinations thereof Thus, any polymerization zone known in the art to produce ethylene-containing polymers can be utilized. For example, a stirred reactor can be utilized for a batch process, or the reaction can be carried Out continuously in a loop reactor or in a continuous stirred reactor.
After catalyst activation, a catalyst, composition is used to homopolymerize ethylene, or copolymerize ethylene with a comonomer. In 'one aspect, a typical polymerization method is a slurry polymerization process (also known as the particle form process), which is well known in the art and is disclosed, for example in U.S. Patent No. 3,248,179, which is incorporated by reference herein, in its entirety. Other polymerization methods of the present invention for slurry processes are those employing a loop reactor of the type disclosed in U.S. Patent No. 3,248,179, and those utilized in a plurality of stirred reactors either in series, parallel, or combinations thereof, wherein the reaction conditions are different in the different reactors, which is also incorporated by reference herein, in its entirety.
In one aspect, polymerization temperature for this invention may range from 60°C to 280°C, and in another aspect, polymerization reaction, temperature may range from 70°C to
In another aspect, the polymerization reaction typically occurs in an inert atmosphere, that is, in atmosphere substantial free of oxygen and under substantially anhydrous conditions, thus, in the absence of water as the reaction begins. Therefore a dry, inert atmosphere, for example, dry nitrogen1 or dry argon, is typically employed in the polymerization reactor.
In still another aspect, the pretreatment pressure can be any pressure that does not terminate the pretreatment step, and typically is a pressure that is suitable for the formation
of organoaluminum metallaeyclic compounds such as aluminacyclopentanes (ACPs), upon precontacting the metalloeene, organoaluminum compound, and an olefin. Pretreatmeat pressures ate typically, but not necessarily, lower Own polymerization pressures, arid generally range from atmospheric pressure to 100 psig (791 kilopascal (kPa)). In one aspect, pretreatment pressures are from atmospheric pressure to 50 psig (446 kPa).
In yet another aspect, (he polymerization reaction pressure can be any pressure that does not terminate the polymerization reaction, and it typically conducted at a pressure higher than the pretreatment pressures. In one aspect, polymerization pressures may be from atmospheric pressure to 1000 psig (7000 kPa). In another aspect, polymerization pressures may be from 50 psig (446 kPa) to 800 psig (5320 kPa). Further, hydrogen can be used in the polymerization process of mis invention to control polymer molecular weight.
When a coporymer of ethylene is prepared according to this invention, comonomer is introduced into the reaction zone in sufficient quantity to produce the desired polymer composition. A typical copolymer composition is generally from 0.01 to 10 weight percent comonomer based on the total weight of the monomer and comonomer, however this co-polymer composition varies outside mis range depending upon the copolymer specification and desired composition. Thus, any amount of copolymer sufficient to give the described polymer composition in the copolymer produced can be used.
Polymerizations using the catalysts of this invention can be carried out in any manner known in the art. Such processes that can-polymerize monomers into polymers include, but: are not limited to slurry polymerizations, gas phase polymerizations, solution polymerizations, and multi-reactor combinations thereof. Thus, any polymerization zone known in the art to produce olefin-containing polymers can be utilized. In one aspect, for example, a stirred reactor can be utilized for a batch process, or the reaction can be carried out continuously in a loop reactor or in a continuous stirred reactor. In another aspect, for example, the polymerizations disclosed herein are carried out using a slurry polymerization process in a loop reaction zone. Suitable diluents used in slurry polymerization are well known in the art and include hydrocarbons, which are liquid under reaction conditions. The term "diluent" as'used in this disclosure does not necessarily mean an inert material, as this term is meant to include compounds arid compositions that may contribute to polymerization process. Examples of hydrocarbons that can be used as diluents include, but are not limited to, cycldhexane, isobutane, n-butane, propane, n-pentane, isopentane, neopentane, and n-
hexane. Typically, isobutane is used as the diluent in a slurry polymerization. Examples of this technology are found hi U.S. Patent Nos. 4,424,341; 4,501,885; 4,613,484; 4,737,280; and 5,597,892; each of which is incorporated by reference herein, in its entirety.
For purposes of the invention, the term polymerization reactor includes any polymerization reactor or polymerization reactor system known in the art that is capable of polymerizing olefin monomers to produce homopolymers or copolymers of the presert invention. Such reactors can comprise slurry reactors, gas-phase reactors, solution reactoni, or any combination thereof. Gas phase reactors can comprise fiuidized bed reactors or tubular reactors. Slurry reactors can comprise-vertical loops or horizontal loops. Solution reactors can comprise stirred tank or autoclave reactors.
Polymerization reactors suitable for the present invention can comprise at least on; raw material feed system, at least one feed system for catalyst or catalyst components, at least one reactor system, at least one polymer recovery system or any suitable combination thereoi'. Suitable reactors for the present invention can further comprise any one, or combination of, a catalyst storage system, an extrusion system, a cooling system, a diluent recycling system, or a control system. Such reactors can comprise continuous take-off and direct recycling of catalyst, diluent, and polymer. Generally, continuous processes can comprise the continuous introduction of a monomer, a catalyst, and a diluent into a polymerization reactor and the continuous removal from this reactor of a suspension comprising polymer particles and the diluent
Polymerization reactor systems of flie present invention can comprise one type or' reactor per system or multiple reactor systems comprising two or more types of reactors; operated in parallel or in series. Multiple reactor systems can comprise reactors connected together to perform polymerization, or reactors (hat are not connected. The polymer can be polymerized in one reactor under one set-of conditions, and then the polymer can be transferred to a second reactor for polymerization under a different set of conditions.
In one aspect of the invention, the polymerization reactor system can comprise at least one loop slurry reactor: Such reactors are known in the art and can comprise vertical or horizontal loops. Such loops can comprise a single loop or a series of loops. Multiple loop reactors can comprise both vertical and horizontal loops. The slurry polymerization can be performed in an organic solvent that eamdisperse the. catalyst and polymer. Examples of
suitable solvents include butane, hexane, cyclohexane, octane, and isobutane. Monomei, solvent, catalyst and any comonomer are continuously fed to a loop reactor when: polymerization occurs. Polymerization can occur at low temperatures and pressures. Reactor effluent can be flashed to remove the solid resin.
In yet another aspect of this invention, the polymerization reactor can comprise at le'ast one gas phase reactor. Such systems can employ a continuous recycle stream containing one or more monomers continuously cycled through the fluidized bed in the presence of th<: catalyst under polymerization conditions. the recycle stream can be withdrawn from fluidized bed and recycled back iitto reaeter. simultaneously polymer product be: die reactor new or fresh monomer added to replace polymerized-monomer. such gas phase reactors comprise ft process for multi-step gas-phase of olerms in which olefins are polymerized gaseous a least two independent zones while feeding catalyst-containing formed a. first zone second zone.> In still another aspect of the invention, the polymerization reactor can comprise a tubular reactor. Tubular reactors can make polymers by tree radical initiation, or by employing the catalysts typically used for coordination polymerization. Tubular reactors can have several zones where fresh monomer, initiators, or catalysts are added. Monomer can be entrained in an inert gaseous stream and .introduced at one zone of the reactor. Initiators, catalysts, and/or catalyst components can be entrained in a gaseous stream and introduced at another zone of the reactor. The gas streams are intermixed for polymerization. Heat and pressure can be employed appropriately to obtain optimal polymerization reaction conditions.
In another aspect of the invention, the polymerization reactor can comprise a solution polymerization reactor. During solution polymerization, the monomer is contacted with the catalyst composition by suitable stirring or other means. A carrier comprising an inert organic diluent or excess monomer can be employed. If desired, the monomer can be brought in the vapor phase into contact with the catalytic reaction product, in the presence or absence of liquid material. The polymerization zone is maintained at temperatures and pressures that will result in the formation of a solution of die polymer in a reaction medium. Agitation can be employed during polymerization to obtain better temperature control and to maintain uniform polymerization mixtures throughout the polymerization zone. Adequate means are utilized for dissipating the exothermic heat of polymerization. The polymerization can be
effected in a batch manner, or in a continuous manner. The reactor can comprise a series o!:~ at least one separator that employs high pressure and low pressure to separate the desired polymer.
In a further aspect of the invention, the polymerization reactor system can comprise the combination of two or more reactors. Production of polymers in multiple reactors car include several stages in at least two separate polymerization reactors interconnected by a transfer device making it possible .to transfer the polymers resulting from the first: polymerization reactor into the second reactor. The desired polymerization conditions in one: of the reactors can be different from the operating conditions of the other reactors, Alternatively, polymerization in. multiple reactors can include the manual transfer of polymer from one reactor to subsequent reactors for continued polymerization. Such reactors can include any combination including, but not limited to, multiple loop reactors, multiple gas reactors, a combination of loop and gas 'reactors, a combination of autoclave reactors or solution reactors with gas at loop reactors, multiple solution reactors, or multiple autoclave reactors.
In another aspect of this invention, the catalyst can be made in a variety of methods, including, hut not limited to, continuously feeding the catalyst components directly into the polymerization reactor, including at least one -optional precontacting step of some or all the catalyst components prior io introducing them into the reactor. In this aspect, each optional precontacting steps can involve precontacting for a different time period. In this aspect, the invention can encompass multiple, optional precontacting. steps, for multiple time periods, prior to initiating (be polymerization reaction. Further, these multiple, optional precontacting steps can take place in at least one precontacting vessel prior to introducing the precontacted components into the reactor, they can take place in the polymerization reactor itself, or any combination thereof, including the use. of multiple precontacting vessels comprising different catalyst components. Thus, in mis aspect, any precontacting steps can encompass precontacting of any combination of catalyst components, including any optional catalyst components. Also in this aspect, the multiple, optional precontacting steps can involve different precontacting time periods.
In another aspect of this invention, the catalyst can be made by continuously feeding die catalyst components into any number of optional precontacting vessels and subsequently
introducing the components continuously Into flic reactor. In one aspect, for example, ifa present invention provides a process to produce a catalyst composition, comprising:
contacting at least one metallocene, at least one organoaluminum compound, and at least one olefin or alkyne for a first period of time to form a precontacted mixture comprising at least one precontacted metallocene, at least one precontacted organoalurnininn compound, and at least one precontacted olefin or alkyne; and
contacting tho precontacted mixture with at least one acidic activator-support for a second period of time to form a postcontaeted mixture comprising at least one postcontaeted metallocene, at least one posteontacted organoaluminum compound, at least one postcontaeted olefin or alkyne, and at least one posfcontacted acidic activator-support.
In another aspect, for example, the present invention provides a process to produce ;i catalyst composition, comprising:
contacting at least two, catalyst components comprising at least one metallocene, at least one organoaluminum compound, at least one olefin or alkyne, or at least one acidic activator-support for a first period of time to form a precontacted mixture comprising precontacted catalyst components; and
contacting OK precontacted mixture with any catalyst components not used to fonn the precontacted mixture, and optionally contacting the precontacted mixture with additional catalyst components comprising at least one metallocene, at least one organoaluminum compound, at least one olefin or alkyne, or at least one acidic activator-support for a second period of time to form a postcontaeted mixture comprising at least one postcontaeted metallocene, at least one posfcontacted organoaluminum compound, at least one postcontaeted olefin or alkyne, and at least one postcontaeted acidic activator-support.
In another aspect, each ingredient can be fed to the reactor, either directly or through at least one precoatacting vessel, using known feeding, measuring, and controlling devices, such as pumps, mass and volumetric flow meters and controllers, and die like. Feed-hack signals and control loops can be used in connection with ibis continuous catalyst formation and introduction. The mass flow meter can be a coriolis-type meter adapted to measure a variety of flow types such as from a positive displacement-type pump with three heads. Other types of pumps, meters, and combinations of similar types of devices can be used as means for feed and control to measure and control a feed Tate of a catalyst component.
Various combinations of means for feed and control can also be used for each respective component depending upon the type of component, chemical compatibility of the component, and the desired quantity and flow rate of the component, and as well known to one of ordinary skill in the ait. For example, a suitable meter for means for feed and control can be, but is not limited to, a thermal mass flow meter, a volumetric flow meter such as an orifice-type, diaphragm-type, a level-type meter, or the like.
In another aspect, the catalyst components can he combined in a variety or different orders and combinations prior to being introduced into the polymerization reactor. In one aspect, for example, the metallocene can be precontacted with an aluminum alkyl and an olefin in a first precontacting vessel, for a first precontacting time, for example, up to 7-ID days, to form a first precontacted solution. This first precontacted solution can then be fed to a second precontacting vessel along with the treated solid oxide component, and optionally more aluminum alkyl, for a second precqntacting time. Jn this aspect, for example, th<: second precontacting time can be shorter longer or the same as first time. for example hour .after which mixture fed from vessel directly into reactor itself. in another aspect of mis invention all catalyst components brought together the: period prior to being introduced reactor.> In another aspect, a portion of eatb catalyst component can be fed into the reactor directly, while the remainder is fed into a precontacting vessel. In mis aspect, for example, it is sometimes desirable to limit the exposure of the metallocene or treated solid oxide to the aluminum alkyl, in which casje only a small amount of aluminum alkyl can be introduced into the precontacting vessel, either alone or from a solution also containing the olefin and metallocene, while the remainder of the aluminum alkyl can be fed directly into the reactor. Likewise, the amount of olefin fed as part of the catalyst preparation may be fed from multiple sources. For example, 1-hexene may be added to .the metallocene solution in a first precontacting step to form a first precontacted solution, more 1-hexene may be added separately in a second precontacting step to form a second precontaqted solution, and still more 1-hexene may be added directly to' the reactor. Similarly any of the other catalyst components pan also be added in multiple steps to the entire reactor system.
After the polymers are produced, they can be fanned into various articles, including but not limited to, household containers, utensils, film products, drums, fuel tanks, pipes, geomembranes, and linens. Various processes can fbrra these articles. In one aspect, additives and modifiers can be added to the polymer in order to provide particular desired effects.
Definitions
In order to more clearly define the terms used herein, the following definitions tire provided. To the extent that any definition or usage provided by any document incorporated herein by reference conflicts wife the definition or usage provided herein, the definition or usage provided herein controls.
The term polymer is used herein to mean horaopolymers comprising ethylere, copolymers of ethylene and another olefinic comonomcr, or any combination thereof. The term polymer is also used herein to mean homoporymers and copolymers of acetylenes.
The term cocatalyst is used herein to refer to the at least one organoaluminum compound mat constitutes a. component Of Che catalyst mixture. Typical coeatalysts are trialkyl aluminum compounds, difilkyl aluminum halide compounds, and alkyl aluminum dihalide compounds.. The term cocatalyst may be used regardless of the actual function of the compound or any chemical mechanism by which the compound may operate.
The term inert atmosphere is used herein to refer to any type of ambient atmosphere mat is substantially unreactive toward .the particular reaction, process, or material around which the atmosphere surrounds or blankets. Thus, this term is typically used herein to refer to the use of a substantially oxygen-free and moisture-free blanketing gas, including but noi: limited to dry argon, dry nitrogen, dry helium, or mixtures thereof, when any precursor, component, intermediate, or product of a reaction or process is sensitive to particular gases 01 moisture. Additionally, inert atmosphere is also used herein to refer to the use of dry air as a blanketing atmosphere when the precursors, components, intermediates, or products of the reaction or process are only moisture-sensitive and not oxygen-sensitive. However, inert atmosphere as used herein would typically exclude CQz ox CO because these gases would be expected to be reactive toward the particular reaction, process, or material around which they would surround or blanket, despite their occasional use as inert blanketing gases b other processes.
The term precontacted mixture is. used herein to describe a first mixture of catalyst components that are contacted for a first period of time prior to the first mixture being used to form a postcontacted or second mixture of catalyst components that are contacted for a second period of time. In one aspect of the invention, the precontacted mixture describes a mixture of metallocene, olefin or alkyne monomer, and organoaluminum compound, before this mixture is contacted with the acidic activator-support and optionally an organoaluminum compound. Thus, precontacted describes components that are used to contact each other, hut prior to contacting the components in die second,, postcontacted mixture. Accordingly, this invention may occasionally distinguish between a component used to prepare the precontacted mixture and that component after the mixture has been prepared. For example, according to this description) it is possible for the piecontacted organoaluminum compound, once it is admixed with the metalldcehe-aod the olefin or alkyne monomer, to have reacted to form at least one different chemical compound, formulation, or structure from the distinct organoaluminum compound used to prepare 'the precontacted mixture. In this case, the precontacted organoaluminum compound1 or component is described as comprising an organoaluminum compound that Was used to prepare the precontacted mixture.
Similarly, the term postcontacted mixture is .used herein to describe a second mixture of catalyst components that ate contacted for a second period of time, and one constituent of which is the preeontacted or first mixture of catalyst components that were contacted for a first period of time. Typically, the term postcontacted mixture is used herein to describe Ibe mixture of metallocene, olefin or alkyne monomer, organoaluminum compound, and aciclic activator-support, formed from contacting the precontacted mixture of a portion of these components with the any additional components added to make up the postcontacted mixture. Generally, the additional component added to make up the postcontacted mixture is the acidic activator-support, and optionally may include an organoaluminura compound the same or different from the organoaluminum compound, ased to, prepare the precontacted mixture, as described herein. Accordingly, this invention may also occasionally distinguish between a component used to prepare the postcontacted mixture and that component after the mixture has been prepared.
The term metaHocene is used herein to refer to metaBocene and metallocene-like compounds containing at least one TJ5-alkadieny] ligand, in one aspect at least one T)S-cycloalkadienyl ligand, and in another aspect at least one r)S-cyclopentadienyl ligand, or its
analogs or derivatives. Thus, the meteflocenes of this invention typically comprise at least one cyclopentadienyl, indenyl, fluorenyl, orTjoralabenfceiie ligand, or substituted derivatives thereof. Possible substituents on these, ligands include hydrogen, therefore the description "substituted derivatives thereof" in this invention comprises partially saturated ligands such as tetrahydroindenyl, tetrahydrofluorenyl, octahydrofluorenyl, partially saturated indenyl, partially saturated fluorenyl, substituted partially saturated indenyl, substituted partially saturated fluorenyl, and the like. In some contexts, the metallocene may be referred to simply as the "catalyst", in much the same way the term "cocatalysf1 may be used herein to refer to an organs-aluminum compound.
The terms catalyst composition, catalyst mixture, and the like are used herein to refer to either the preeontacted mixture or the postcontacted mixture as the context requires. The use of these terms does not depend upon the actual product of the reaction of the components of the mixtures, the nature of the active catalytic site, or the fate of the aluminum cocatalyst, metallocene compound, olefin or alkyne monomer used to prepare the preeontacted mixture, or the specific reactions of the acidic activator-support after combining these component;. Therefore, the terms catalyst composition, catalyst mixture, and the like include both heterogeneous compositions and homogenous compositions.
The term hydrocarbyl is used to specify a hydrocarbon radical group that includes, but is not limited to aryl, alkyl, eycloalkyl, alkeayl, cycloalkenyl, cycloalkadienyl, alkynyl, aralkyl, aralkenyl, aralkynyl, and the like, end includes all substituted, unsubstituted, branched, linear, heteroatom substituted derivatives thereof.
The terms solid acidic activator-support, acidic activator-support, or simply activator-support, and the like are used herein to indicate, a treated, solid, inorganic oxide of relatively high porosity, which exhibits Lewis acidic or Brernsted acidic behavior, and which has beer, treated with an electron-withdrawing component, typically an anion, and which is calcined The electron-withdrawing component is typically an electron-withdrawing anion source compound. Thus, in one aspect, the treated solid oxide compound comprises the calcined contact product of at least one solid oxide compound with at least one electron-withdrawing anion source compound. In another aspect; the activator-support or "treated solid oxide compound" comprises at least one ionizing, acidic solid oxide compound. The terms support or activator-support are not used to imply these componentE are inert, and this component should not be construed as an inert component of the catalyst composition.
Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the typical methods, devices and materials are herein described.
All publications and patents mentioned herein are incorporated herein by reference for the purpose of describing and disclosing, for .example, the constructs and methodologies thai, are described in the publications, which might be used in connection with the presently described invention. The publications discussed above and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is; to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.
For any particular, compound disclosed herein, any general structure presented also encompasses all conformational isomers, regioisomers, and stereoisoraers that may arise from, a particular set of substitutents. The genera] structure also encompasses all enantiomers, diastereomers, and other optical isomers whether in enantiomeric or racemic forms, as well as; mixtures of stereoisomers, as the context requires.
The present invention is further illustrated by the following examples, which are not to be construed in any way as imposing limitations upon the scope thereof. On the contrary, it is to be clearly understood that resort may be had to various other aspects, embodiments, modifications, and equivalents thereof which, after reading fee description herein, may suggest themselves to one of ordinary Skill in the art without departing from the spirit of the present invention or the scope of the; appended claims.
In the following examples, unless otherwise specified, the syntheses and preparations described therein were carried out under an inert atmosphere such as nitrogen or argon. Solvents were purchased from commercial sources and were typically dried over activated alumina prior to use; Unless otherwise specified, reagents were obtained from commercial sources.
EXAMPLE! -Preparation of a Fluoride^ Silica-Alumina Acidic Activator-Support
The silica-alumina used to prepare the fluorided silica-alumina acidic activator-support in this Example was obtained from W.R. Gtace as Grade MS 13-110, containing 13%
alumina, having a pore volume of 1.2 co/g and a surface area of 400 ra2/g. This material wiis fluorided by impregnation to incipient wetness with a solution containing ammoaiu-n bifluoride in an amount sufficient to equal 10 wt % of the weight of the silica-alumina. This impregnated material was then dried in a vacuum oven for 8 hours at 100°C. The thus-fluorided silica-alumina samples were then calcined as follows. 10 grams of the alumina were placed in a 1.75-inch quartz .tube fitted with a sintered quartz disk at the bottom. While the silica was supported on the disk, dry air .was blown up through the disk at the linear rale of 1.6 to 1.8 standard cubic feet per hour. An electric furnace around the quartz tube was used to increase the temperature of the tube at the rate of 400°C per hour to a finiJ temperature of 450°C. At this temperature,' the silica-alumina was allowed to fluidize for three hours in the dry air. Afterward, the silica-alumina was collected and stored under dry nitrogen, and was used without exposure to the atmosphere.
EXAMPLE 2
Preparation of a Precdntacted/Pastcontaeted Catafyst Composition aruf Comparison of its Polymerization Activity with a Standard Catafyst Composition
The present invention was tested in a .comparative study of a catalyst composition comprising bis(cyclopentadienyl)2drcorrium dichloride catalyst, triethylaluminum (TEA), monomer (ethylene) and cbmonomer (l A stock solution of 45 mg of bis(cyclopetttadi«ryl)zirconium dichloride in 45 mL of dry, degassed toluene was prepared for the experiments of Table 1. Control Example 2 A of Table 1 represents .polymerization data obtained from the near simultaneous contacting of 5 mL of the bis(cyclopentadieoyl)zircoraum dichloride stock solution, 200 mg of fluorided silica alumina, 1 mL of 15 wt. % triethylalutninum (TEA) in heptane, 20 g of cornonomer (1-hexene) and monomer (ethylene), withput extended precontacting of any catalyst components.
The polymerization reaction was carried out in a 1-gallon (3.785 L) autoclave as follows. Under an isofautane purge 5 mL of the bis(cyclopesitadienyl)zirconiwn dichloride stock solution, immediately foUdwed by 200 mg, of support-activator, was charged to the
autoclave. The autoclave was sealed, 2 lifers of isobutane Were added, along with 20 g of I -hexene and 1 mL of 15 wt % triethylaluminum (TEA) in heptane. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 90"C over a period of 2 minutes. The total pressure was brought to 550 psig (3890 ,kPa) with ethylene. Ethylene was fed to hie reactor on demand to maintain the pressure at 550 psig (3890 kPa). After 1 hr, the stirrer and heating were then stopped and the reactor wasiapidry depressurized. The autoclave was then opened and the solid polyethylene was physically removed. The activity values provided in Example 2 A of Table 1 provide a baseline of catalyst and activator activity for comparison.
Example 2B of Table 1 demonstrates mat precoitacting bis(cyclopentadienyl)-zirconium dichloride with 1-hexene and TEA prior to charging to the autoclave gave a catalyst that exhibited higher activity than that of Example 2A. Thus, 5 mL of the metallocene stock solution was treated with 2 mL of 1-hexene and 1 mL of 15 wt. % TEA in heptanes. This solution was stirred for 30 minutes prior to charging to the autoclave. This precontacted solution was then charged to the 1 gallon (3.785 L) autoclave immediately followed by 200 mg of the activator-support. The autoclave was men sealed and 2 L of isobutane, along with 20 g of 1-hexene, were quickly added to the reactor. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 90°C over a period of 2 minutes. The total pressure was brought to 550 psig (3890 kPa) with ethylene. Thus, the postcontacted mixture, containing the precontacted solution and the support activator, was allowed to remain in contact for a period of 2 minutes prior to introducing ethylene. Ethylene was fed to the reactor on demand to maintain; the pressure at 550 psig (3890 kPa). After 53 minutes, the stirrer and heating were then stopped and the reactor was rapidly depressurized. The autoclave was then opened and the solid polyethylene was physically removed. The reactor had substantially no indication of any wall scale, coating or other forms of fouling following the reaction.
(Table Remove)
(Table Remove)
EXAMPLES
Comparison of the Polymerization Activity of Catalyst Compositions Prepared by Varying the Components that are Precontacted and Postcontacted
In Examples 3A-3D presented in Table 2, 1 mL of & 1 rag/1 mL toluene stock solution of bis(cyclopentadienyl)zirconium dichloride was optionally treated, in various combinations, with 1 mL of 15 wt % triethylaluminum, 2 mL of 1-hexene, and 200 mg of a fluorided silica-alumina activator-support for 30 minutes before introduction of this mixture to tho polymerization autoclave. The stock solution was prepared under an atmosphere of nitrogen by dissolving 45 mg of bis(eyclppentadienyj)zrrc In Example 3A, 1 mL of 'img/lmL toluene stock solution oi' bis(cyclopentadienyl)zirconium dichloride 'Was treated with both 1 mL of 15 wt % trialkylaluminum in heptane and 2 mL of 1-hexene, under an atmosphere of nitrogen. This precontacted mixture composition containing these three reagents was stirred for 30 minutes before being charged to the autoclave. This precontacted solution was then charged to the 1 gallon [3.785 L) autoclave immediately followed by 200 mg of the activator-support. The autoclave was then sealed and 2 L of isobutane, along with 20 g of 1-hexene, were quickly added to the reactor. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 9Q°C over a period of 2 minutes. The total pressure was brought to 550 psig (3890 kPa) with ethylene; Thus, the postcqntacted mixture, containing the precontacted solution and the support activator, was allowed to remain in contact for a period of 2 minutes prior to introducing ethylene. Ethylene was fed to the reactor on demand to maintain the pressure at 550 psig (3890 kPa). After 60 minutes, the'stirrw and heating were then stopped and the reactor was rapidly depressurized. The autoclave was then opened and the solid polyethylene
was physically removed. The reactor had substantially no indication of any wall scale, coating or other forms of fouling' following the reaction.
In Example 3B, 1 mL of the Img/lihL toluene stock solution of bis(cyclopentadienyl)zirconium dichloride was treated only with 1 mL of 15 wt. % triethylaluminum in the precontacted mixture. This precontacted mixture composition containing these two reagents was stirred' for 30 minutes before being charged to the autoclave. This precontacted solution was then charged to the 1 gallon (3.785 L) autoclave immediately followed by 200 mg of the activator-support, The autoclave was then sealed and 2 L of isobutane, along with 20 g of 1-hexene, were quickly added to the reactor. Stirring; was initiated and maintained at 700 rpm as the reactor was heated to 9Q°C over a period of 2 minutes. The total pressure was brought to 5SO psig (3890 kPa) with ethylene. Thus, the posteontacted mixture, containing the precontacted solution and the support activator, was allowed to remain in contact for a period of 2 minutes prior to introducing ethylene. Ethylem; was fed to the reactor on demand to maintain the pressure at 550 psig (3890 kPa). After 60 minutes, the stirrer and heating were then stopped and the reactor was rapidly depressurized The autoclave was then opened and the solid polyethylene was physically removed. The reactor had substantially no indication of any wall scale, coating or other forms of fouling following the reaction. This Example gave a lower activity than Example 3 A.
In Example 3C, 1 mL of the Img/lmL toluene stock solution of bis(cyclopentadiehyl)zirconium dichloride was treated only with 2 mL of 1-hexene in the precontacted mixture. This precontacted mixture composition containing these two reagents was stirred for 30 minutes before being charged to the autoclave. This precontaeted solution was then charged to the 1 gallon (3.785 L) autoclave immediately followed by 200 mg of the activator-support The autoclave was then sealed and 2 L of isobutane, along with 20 g of 1-hexene and 1 mL of 15 wL % triethylaluminum, were quickly added to the reactor. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 90°C over a period of 2 minutes. The total pressure was brought to 550 psig (3890 kPa) with ethylene. Thus, the posteontacted mixture, containing the precontacted solution and the support activator, was allowed to remain in contact for a period of 2 minutes prior to introducing ethylene. Ethylene was fed to the reactor on demand to maintain the pressure at 550 psig (3890 kPa). After 60 minutes, the stirrer and heating were then stopped and the reactor was rapidly depressurized. The autoclave was then opened and the solid polyethylene was physically removed. The
reactor had substantially no indication of any wall scale, coating oz other forms of fouling following the reaction. This Example give a lower activity than Example 3 A.
In Example 3D, 1 raL of- the Img/lmL toluene stock solution of bis(eyclopentadienyl)arconinm diehlorido was treated with 2 mL of I-hexene and 200 tag of the activator-support in the pre-contacled mixture. This preeontacted mixture composition containing these three reagents was stirred for 30 minutes before being charged to thtt autoclave. This precontacted slurry was then charged to the 1 gallon (3.785 L) autoclave; immediately followed by 200 mg of .the activator-support. The autoclave was men sealed ant 2 L of ispbutane, along with 20 g of 1-hexene and 1 mL of 15 wt % triethylalummum, were quickly added to the reactor. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 90°C over a period of 2 minutes. The total pressure was brought to 550 psig (3890 kPa) with ethyiene. Thus, the postcontacted mixture, containing the precontacted solution and the support activator, was allowed-to remain in contact for a period of 2 minutes prior to introducing ethyiene, Ethylene was fed to the reactor on demand to maintain the pressure at 550 psig (3890 kPa). After 60 minutes, me stirrer and heating were then stopped and the reactor was rapidly depressurized. The autoclave was then opened and the solid polyethylene was physically removed. The reactor had substantially no indication of any wall scale, coating or other forms of fouling following the reaction. This Example gave a lower activity than Example 3A,
These experiments demonstrate the higher activity for precontacting the metaEocene with both 1 -hexene and TEA in the absence of activator-support.
EXAMPLE4 .
Activity of Catalysts Derived from Vydoiis Precontacted and Postcontacted Catalyst Compositions and Study of the Presence of the Activator-Support in the Precontactoi Catalyst Composition
Experiments 4A and 4B presented in Table 3 provide a comparison of catalyst compositions comprising the metallocene catalyst, bis(2,7-di-fcrf-bu1ylfluorenyl)-eflian-l^-diylzJK5oniura(IV) dichloride, triethylahqninum (TEA), monomer (ethylene} and comonomcr (1-hexene), and fluorided silica-alumina -activator-support A 1 rag metallocene/1 ml, toluene stock solution (6 tnL) was optionally treated with 1 mL of 15 wt. % triethylahiminum, 2 mL of 1-hexene, and 200 mg of fluorided silica-alumina activator-support for 45 minutes before introduction to .the polymerization autoclave, according to the data in Table 3. Thus, a "yes" a* "no" entry; in Table 3 indicates the presence of thesis reagents in a 45 minute precontact step; with the metallocene, prior to introducing the precontacted mixture to the autoclave. Polymerizations were conducted for 60 minutes in isobutane at 80°C, 450 psig (3200 kPa) ethylene, with 20 grams of 1-hexene.
In Example 4A, under an atmosphere of nitrogen, 6 mL of Img/lmL toluene stock: solution of the bis(2t7-di-r^f4mtylflaoreiiyI)-ethan-1^2-diylzirconiuni(IV) dichloride metallocene was treated with both 1 mL of-15wt % triaflg«lalummum in heptane and 2 mL of 1-hexene. This precontacted mixture composition containing these three reagents was stirred for 45 minutes before being charged to the autoclave. This precontacted solution was then charged to the 1 gallon (3.785 L) autoclave immediately followed by 200 mg of the activator-support The autoclave was then sealed and 2 L of isobutane, along .with 20 g of 1-hexene, were .quickly added to this; reactor. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 80°C over a period:of 2 minutes. The total pressure was brought to 450 psig (3200 kPa) with ethylene. Thus, the postcontacted mixture, containing the precontacted solution and the support activator, was allowed to remain in contact for a period of 2 minutes prior to introducing ethylene. Ethylene was fed to the reactor on demand to maintain the pressure at 450 psig (3200 kPa). After $0 minutes, die stirrer and heating were then stopped and the reactor was rapidly depiessuijzed. The autoclave was then opened and the solid polyethylene was physically removed.
(Table Remove)
In comparative Example 4B, the fluorided silica-alumina activator-support was present in die precontacted mixture along with the bis(2,7-di-tert-butylflnorenyl)-ethan-l,2-diylzirGonium(IV) dichloride metallocene catalyst, triethylaluminum (TEA), and hexane comonomer. Thus. 6 mL of a Img/lmL tpluenc stock solution of metallocene was slurried with 1 mL of 15wt % trialkyjaluminum in heptane, 2 mL of 1-hexene, and 200 mg of the activator-support. This precontacted mixture containing all four catalyst components was stirred for 45 minutes before being charged to an autoclave. The autoclave was then sealed and 2 L of isobutane, along with 20 g of 1-hexene, were quickly added to the reactor. Stirring was initiated and maintained at 700 rpm as the reactor was heated to 80°C over a period of 2 minutes. The total pressure was brought to 450 psig (3200 kPa) with ethylene. Ethylene was fed to the reactor on demand to maintain the pressure at 450 psig (3200 kPa). After 60 minutes, the stirrer tad heating were then stopped and the reactor was rapidly depressurized. The autoclave was then opened and the solid polyethylene was physically removed. As Table 3 indicates, the Example 4B qatalyst exhibited a lower catalyst activity than the Example 4A catalyst.
Preparation of Various Precontacted tmd Postcontacted Catalyst Compositions and Comparison of their Polymerization Activities
The Experiments presented in Table 4 provide a comparison of catalyst compositions comprising the metallocene catalyst, [r|5-«yclcpentadienyl-r|5-(9-fluorenyl) hex-1-ene] zirconium dichloride, CH2=CHCH2CH2G(CH3)(Cp)(9-Fla)ZrCl2, triethylalurainuni (TEA), monomer (ethylene) and comonomer (1-hexene), and fluorided silica-alumina activator-support, both with and without the precontacting step of the metallocene, TEA, and 1-hexene. The metallocene catalyst in mis example, [( C'ijH9)]2rCl2» has the following structure:
(Figure Remove)

wherein Rl is melhyl, R2 is butenyl (-CHzCHaQKBa), and R3 is H.
Example SA represents a standard catalytic run, that was obtained as follows. Under a nitrogen atmosphere, 2 mL of 1-hexene,' 2 roL of a solution of catalyst solution prepared from [T)s-cyclopentadienylrT|S-{9-fhiorBnyl)' bex-1-ene] zirconium dichloride, CH2=CHCHaCH2C(CH3)(CpX9-Flti)ZrCl3, in toluene (2 mg/mL), arid 1 mL of 15 wt. % triethylaluminum in hq>tane solution were added to a Diels-Alder tube. This solution was immediately added to 250 mg of activator-support Thus, Example SA of Table 4 represents polymerization data obtained from . the near simultaneous contacting of CHj=CHCH2CH2C(CH3)(Cp)(?-Flu)ZrCl2, TEA, 1-hexene, and fluorided silica-alumina activator-support, without precontacting the onsa-metallocene, triethylalummum (TEA), and 1-hexene, and therefore provides a baseline .for comparison with Examples SB and SC.
Example SB represents a catalytic run obtained in the same manner as the standard run of Example 5 A, except that Example SB included a precontacting step of 0.25 hours for the metallocene CHiHSHCHzCHjCfCHjjXC^XS-^ZrClsi TEA, and 1-hexene, prior to contacting this mixture with the fluorided silica-alumina activator-support.
Example SC represents a catalytic run obtained in the same manner as the standard run of Example 5 A, except that Example 5C included no precontacting of the metallocene, TEA, and 1-hexene, but instead included a "postcoritacted" step (according to the definitions herein) of 0.50 hours in which all components, namely the metallocete CH2<:hch2ch2c tea l-hexener and we fluorided silicji-alumina activator-support were contacted prior to adding this posteontacted mixture the reactor example demonstrates that an increase in activity is obtained by precontacting metallocene hexane whereas when all reactants are initiating a polymerization run decrease was observed.> Example 5D was prepared as follows. The metallocene catalyst: CH2=CHCH2GH2CCCH3XCp)(9-FUi)Zra2 (24 rag) was placed in a Diels-Alder tube and maintained in the dark by covering the tube with aluminum foil. A 12-mL sample of dry heptane (but no hexene) was added and this mixture was stirred while 2 mL of 15 wL % triethylaluminum in heptane was added. This slurry was stirred in the dark at roorr. temperature for 17 hours, to provide a light yellow solution. This sample was maintained fan the dark until use. Example 5D included a "posteontactbg" step of 0.25 hours for 2 rnLs of this precontacted solution, 1 mL of 15 wt % TEA, and the fluorided silica-alumina activator-support prior to adding to the reactor. Example 5D provides a baseline for comparison of Examples 5E and 5F.
Example 5E was prepared as .follows. The metallocene catalyst CHi=CHCHiCH2C(CHj)(CpK9-Flu)ZrCl2 (24 mg) was placed in a Diels-Alder tube and maintained in the dark by covering the tube with aluminum foil. A 12-mL sample of 1 -hexene was added and this mixture: was stirred while 2 mL of IS wt % triethylaluminum in heptane was added. This slurry was stirred in Hie dark at room temperature for 17 hours, to provide a dark yellow solution in which all the catalyst had .dissolved. This sample was maintained in the dark until use. This Example included a "postcontacting" step of 0.25 hours for 2 mLs of this solution, 1 mL of .15 wt % TEA, and the fluorided silica-alumina activator-support prior to adding to the reactor;
Example 5F was prepared as follows, The metallocene catalyst (10 mg) was placed m a Diels-Alder tube, to which 20 mL of 1-hexene and 2 mL of 15 wt % triethylalurainutn in heptane were added. This mixture was maintained in the dark and the Diels-Alder tube was put m an ultra sonic bath and sonicated for 10 minutes. A dark yellow solution was obtained in which all the catalyst had dissolved. This sample was maintained in the dark until use. This Example included a "postcontacting" step of 0.25 hours for 4 mLs of this solutioni 1 mL of 15 wt % TEA, and the fluorided silica-alumina activator-support prior to adding to the reactor. Examples 5E and 5F show that a large increase in activity is obtained by precontacting the metallocene, TEA and 1-hexene compared to Example 5D, where 1-hexene was excluded.
Polymerization reactions were carried out as follows. Following any preedntact and postcontact steps for a particular sample, a catalyst, slurry (comprising metallocene, organoalummum, olefin, and activator-support) was added to a 1 -gallon (3.785 L) autoclave
under an isobutane purge. The autoclave was sealed, 2 liters of isobutane were added, and stirring was initiated and maintained at 700 tpin. The reactor was quickly heated to 80°C over & period of 2 minutes. A 25-g sample of 1-hexene was forced into the reactor, and the total pressure was brought to 450 psig (3200 kPa) with ethylene. Ethylene was fed to the reactor on demand to maintain me ^pressure at 450 paig (3200 kPa) for 1 hour. The stirrer and heating were then stopped and the -reactor was rapidly depressurized. The autoclave was then opened and (he solid polyethylene was physically removed.
Precontaet Time is defined as the contact time of the metallocene
CH2=CHCH2CHiC(CH3XCp)(9-Fto)a€lj, triethyMumrauin (TEA), and 1-hexene,
which forms the precontacted mixture.
2 Postcontact Time is defined as the contact time between all four components, the
metallocene CH2=CHCH2CHJC(CH3)(Cp)(9-Flu)ZrCl?, triethylaluminum (TEA), 1-
hexene, and fluorided silica-alumiaa activator-support This also represents the
contact time between, precbntacted mixture and the fluonded silica-alumina activator-
support.
3 Because the polymerization rate was decreasing at the end of the 49 minute run, the
activity (g/g/hr) extrapolated to a per hour basis constitutes an overestimate of the
activity.
4 Neither the precontacted nor tike postcontacted mixture contained any olefin
monomer. Thus, the. precontacted mixture contains the metallocene
CHi-€HCHiCH2C(CH3)(Cp)(9-Flu)ZiCli, triefeylalumnnim (TEA), and heptane, but
no 1-hexene. The postcontected mixture contains me precontacted mixture, additional
triethylaluminum (TEA), and fluorided silica-alumina.

5 Precontactesd mknrre maintained in the dark.
6 Precantacted mixtntts sonicated while maintaining in the dark.
In Table 4, Productivity is the g of polymer/g of catalyst produced during that run, Catalyst Activity is the g of polymer/g of catalyst/unit time, and is a better comparison among runs, and Activator-Support Activity is the g of polymer/g of activator-support/unit time.
EXAMPLE 6
Larger Scale Production of Polyethylene Resin Uiing the Preconutcted/Postcontacted Catalyst Composition
In this Example, the pretreated metallocene catalyst of the present invention was USB! in the experimental production of 0.931 density (specification range 0.930 to 0.933) polyethylene resin to demonstrate the capability of the catalyst system to produc; polyethylene polymer in larger scale production.
Ethylene perymers were prepared'in a continuous particle form process (also known as a slurry process) by contacting a catalyst with a monomer and optionally one or more o> olefm comonomers, such as 1-hexene. The medium and temperature are thus selected such that the copolymer is produced as solid particles and is recovered in that form. Ethylene that had been dried over activated alumina and/or molecular sieves was used as the monomei. Isobutane that had been degassed by ftactionation and dried over alumina and/or molecular sieves was used as the diluent
The reactor was a liquid-full 22.5-inch inside diameter pipe loop having a volume of 27,000 gallons (102206.124 L). Liquid isobutane was used as the diluent, and the reactor pressure was 600 psig (4240 kPa), Th&loop reactor was equipped with continuous take-ofir (CTO) and settling leg product take-off (PTO), which can be operated hi combination. The; slurry discharge of polymer and isobutane along with unreacted ethylene and 1-bexene from the reactor went though a heated flashjine into a low pressure flash tank and through a purge column to remove residual hydrocarbons. To prevent static buildup in the reactor, a small amount ( The catalyst system comprised the 'following components. The metallocene bis(indenyl)zirconium dichloride (T^-CsEtjJjZrCla, 1-hexene diluent, and triethylaluminum (TEA) were precontacted for a period of 9 days in a first premixing pot, prior to being introduced into a second "premixing" vessel. After mis time, the metallocene-olefin-TEA mixture constituting one feed, the activator-support slurried in isobutane constituting a
second feed, and additional triethylalurninurn '(TEA) in isobutane constituting a third feed were introduced into the second "prerabdng" vessel to form the postcontacted mixture, according this invention, before introduction into the loop reactor. Once introduced in this second premixing vessel to form the postoontacted mixture, this mixture was stirred with a residence time of approximately 28 minutes, prior.to introduction into the loop reactor.
The raetallocene bis(indenyl)arconium dichloride concemration was approximately 1 part per million of the reactor concentration. The total TEA added was approximately 10 part per million of the reactor concentration. The sotid activator-support component, was dehydrated in a fhridized bed at 950°F (510 °C) to 1000°F (537.8 °C), then charged to the conventional catalyst metering vessel used for.chromium catalyst and metered through a 35 or 49-cc feeder into the second premixing vessel.
Typical and approximate reactor conditions for tins experimental run were: 190°F (87.78 °C) reactor temperature, 5.5 to 7.0 weight percent emylens measured in the off-gas from the low pressure flash chamber via. on-line gas chromatography, 3.5 to 4.5 weight percent 1-hexene measured, in the off-gas froth the low pressure flash chamber via on-line gas chromatography, no hydrogen, and reactor solids up to 38 weight percent.
The reactor was operated to..have a residence time of 45 minutes to 1.5 hours. At steady state conditions, the isobutane feed rate was 30,000 pounds (13607.77 kg) to 36,000 pounds (16329.33 kg) per hour, the ethylene feed rate was 30,000 pounds (13607.77 kg) to 34,000 pounds (15422.14 kg) per hour, and -the 1-hexene feed rate was varied to control the density of the polymer product Ethylene concentration in the diluent was 5 to 7 weigh): percent Catalyst concentrations in the reactor can be such mat the catalyst system content ranges from 0.001 to 1 weight percent baaed on the weight of the teaetoi contents. Polymer was removed from the reactor at me rate of 33,000 pounds (14968.55 kg) to 37,000 pounds (16782.92 kg) per hour and recovered hi a flash chamber.



We Claim:
1. A catalyst composition comprising:
at least one precontacted metaUpcene;
at least one precontacted organoaluminum compound;
at least one precontacted olefin or alkyne; and
at least oneposteontacted acidic activator-support
2. The catalyst composition of Claim 1, wherein the postcontacted acidic activatoT-
support comprises a Solid oxide treated with an electron-withdrawing anion, wherein:
the solid oxide is silica, alumina, silica-alumina, aluminum phosphate, heteropolytungstates, titania, zareonia, magnesia, boria, zinc oxide, mixed oxides thereof, or mixtures thereof; and
the electron-withdrawing anion is fluoride, chloride, bromide, phosphate, Inflate, bisulfate, sulfate, or any combination thereof.
3. The catalyst composition of Claim 1, wherein the postcontacted acidic activator-
support comprises fluorided silica-alumina.
4. The catalyst composition of Claim 3 wherein the fluorided silica-alumina comprise:;
from 5% to 95% by weight alumina and from 2% to 50% by weight fluoride ion, based on the:
weight of the fluorided silica-alumina after drying but before calcining.
5. The catalyst composition of Claim 3, wherein the fluorided silica-alumina comprise:;
silica-alumina having a pore volume greater man 0.5 cc/g, and a surface area greater than IOC
m'/g.
6. The catalyst composition of Claim 1, wherein the precontacted metallocene comprises
a compound having the following formula:
wherein M1 is titanium, zirconium, or hafnium;
wherein (X1) is independently cyclgpentadienyl, indenyl, fluorenyl, boratabenzens, substituted cyclopentadieiryl, substituted indenyl, substituted fluorenyl, or substituted borittabenzene;
wherein each substituent on the substituted cyclopentadienyl, substituted indenyl, substituted fluorenyl or substituted boratabenzene of (X1) is independently an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group* a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen;
wherein at least one substituent on (X1) is optionally a bridging group that connects (Xl)and(X2);
wherein (X3) and (X4) are independently an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a-boron group, an aluminum group, an inorganic group, an OTganometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide.
wherein (X*) is independently a cyclopentadienyl group, art indenyl group, a fluorenyl group, a boratabenzene group, an aliphatic group, an aromatic group, a cyclic group, ;i combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron .group, an aluminum group, an inorganic group, an organometallic group, qr .a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide;
wherein each substituent oa the substituted (X2) is independently an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxyget. group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen; and
wherein at least one substitnent on (X2) is optionally a bridging group that connects OX1) and (X1).
7. The catalyst composition of Claim 1, wherein the precontacted metallocene comprises a metallocene compound comprising:
bis(cyclopentadienyl)haftrium dichloride;
biS(Cyclopentadieny!)zirconiuni dichloride;
l,2-ethanediylbis(T|5-l-iiidenyl)di-n-butoxyhafiiitnn;
l,2>ethanediylbis(iis-l-indenyl)dime|hylziiconiuni;
methylphenylsilylbis(r| 5-4,5,6,7-tetrahydro-l-indenyl)zircoiuum dichloride; bis(n-butylcyclop«iitadienyl)bis(r-butylamido)hafiiiuin; bis( 1 -rt-butyI-3-methyl-cyclopentHdienyl)zirconiurn dichloride; bis(n-butylcyolopentadienyl)zirconiurh dichloride; dhnethylsilylbis( 1 -indenyl)zirconium dichloride; octylphenylsilylbis( 1 -indenyl)hafiuum dichloride; diraethylsilylbi^TiM.S.dJ-tetrahydro-l-indenyyziTConiura dichloride, dimeihylsilylbis(2-meQtyI-l-indenyl)zirconitnndicUoride; l,2-ethanediylbis(9-fiuorenyl)zirconium dichloride; indenyl diethoxy titaniuni(TV) chloride;
(isopropylamidodimethylsilyl)cyclopentadienyltitanium dichloride;
bis(pentamethylcyc!opentadicnyl)zircoiiium dichloride;
bis(indenyl) zirconium dichloride;
methyloctylsUylbis(9-fluorenyl)zirconium dichloride;
bis(2J-di bis-[l-^»K-diisopTopyUunino)botatabeiizenejhydridozireonium
trifluoromethylsulfonate; .
methyl-34»utenyhrietnyUdene(T]S-c^opentaidienyl)(Tis-9-fluorenyl)zirconium dichloride;
meftyl-3-butenylmefliyUdeneCTiJ^clopentadienyl)(Tis-2,7-di-f-butyl-9-flaorenyl)-zirconiuni dichloride;
dichloride;
met fluorenyl)zirconium dichloride;
dichloride;
phenyI-3-butenybn^iylidene(Tis-cyclopentzdieiV5fl)(TiJ-2,7-di^--butyl-9-fluorenyl)zirconium dichloride;
phenyW-pentefflytaelhyMdene(V-K^lopenla& dichloride; or
phenyl4-r^lenylme%lidene(ns 8, The catalyst composition of Claim 1, wherein the precontacted organoaluminum compound comprises an organoaluminum compound with me following formula:
wherein (X5) is a hydrocarhyl having from 2 to 20 carbon atoms; (X6) is an alkoxide or aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride; and n is a number from 1 to 3, inclusive.
9. The catalyst composition of Claim I, wherein the precontacted organoaluminum
Compound comprises triethylaluminum (TEA), tripropylaluminum, diethylaluminum
ethoxide, tributylaluminum, disobutylahiminum hydride, triisobutylaluminum,
diethylahiminum chloride, or combinations thereof.The catalyst composition of Claim .1, farther comprising at least one postcontacted
organoahiminum compound with Die following formula:
wherein (Xj) is a hydrqcarbyl having from 1 to 20 carbon atoms; (X6) is an alkoxide 01 aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride; and n is a number from 1 to 3, inclusive.
11. The catalyst composition of Claim lj wherein the precontacted olefin or alkyne comprises a compound having from 2 to 30 carbon atoms per molecule and having at least one carbon-carbon double bond or at least one carbon-carbon triple bond.
12. The catalyst composition of Claim 1, wherein the preeontacted metallocene comprise:;
to(indenyl)zirconiuni dichloride, 6w(cyclopentadieiryl)2ircbnrara dicWoride, or bis(2,7-di-
fert-butylfluprenyl)-ethan-l,2-diyl)zireonium{IV) dichloride; the precontacted
organoaluminum compound comprises trietfaytaluminum; the precontacted olefin comprises
I -hexene; and .the postcontaeted acidic activator-support comprises fiuorided silica-alumina.
13. Th* catalyst composition of Claim 1, wherein the precontacted organoaluminum
compound comprises an aluminacyclopentane, an aluminacyclopentadiene, or an
aluminacyclopentene.
14. The catalyst composition of Claim I, wherein the mole ratio of the metallocene to the:
organoaluminum compound is from 1:1 to 1:10,000.
15. The catalyst composition of Claim I, wherein the mole ratio of the olefin or alkyne tc
the metallocene in the precontacted mixture is from 1:10 to 100,000:1.
16. The catalyst composition of Claim 1, wherein the weight ratio of the metallocene tc
the acidic activator-support is from 1:1 to 1:1,000,000.
17. The catalyst composition of Claim 1, wherein fte weight ratio of the acidic activator-
support to the oiganoahimmum compound is. from 1:5 to 1000:1.
1 8. The catalyst composition of Claim 1, wherein the precontacted metallocene comprises a compound with the formula I:
wherein E is C, Si, Ge, or Sii; Rl is H or a hydrocarbyl group having from 1 to 12 carbon atoms; R2 is an alkenyl group having from 3 to 12 carbon atoms; and R3 is H or a hydrocarbyl group having from 1 to 12 carbon atoms.
19. The catalyst composition .of Claim 1, wherein the precontacted metalloeene comprises a compound with the formula II:


wherein Rl is methyl or phenyl; R2 is 3%Jtenyl (-CHjCHaCH-CHb) or 4-pentenyl (-CH2CH2CH2CH=CHZ); and R3 is H or /-butyl.
20. A process to produce a catalyst composition, comprising:
contacting at least one metalloeene, at least one ofganoaluminum compound, aiid at least one olefin or alkyne for a first- period of time to ibrm a precontacted mixture comprising at least one precontacted metalloeene, at least one precontacted organoaluminurn compound, and at least one precontacted olefin or alkyne; and
contacting the precontacted mixture with at least one acidic activator-support for a second period of time to form a postcontacted mixture comprising at least on: postcontacted metalloeene, at least one postoontacted organoaluminum compound, at least one postcontacted olefin or alkyne, and at least one postcontacted acidic activator-support.
21. The process of Claim 20, wherein the metalloeene, the organoaluminum compound,
and the olefin or alkyne are precontacted for a first period of time from 1 minute to 9 days in
the precontacted mixture.
22. The process of Claim 20, wherein the'precontacted mixture and the acidic activator-
support are contacted for a second period of time from 1 minute to 24 hours hi the:
postcontacted mixture.
23. The process of Claim 20, wherein the precontacted metalloeene comprises a
metalloeene compound with the following formula:
•wherein M1 is titanium, zirconium, or hafnium;
wherein (X1) is. independently cyclopentadienyl, indenyl, fluorenyl, boratabenzene, substituted cyclopentadienyl, substituted indenyl, substituted fluorenyl, or substituted boratabeittene;
wherein each substituent on the substituted cyclopentadienyl, substituted indenyl, substituted fluorenyl or substituted botatabehzene of (X1) is independently an aliphatic .group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulfur group, ft nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, •an aluminum group, an inorganic group, an organometaDic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen;
wherein at least one substituent on (X1) is optionally .a bridging group that connects (X')and(XJ);
wherein .(X3) and (X4) are independently an aliphatic group, an -aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an oxygen group, a sulrur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group.* a boron group, an aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide.
wherein (X2) is independently a cyclopentadienyl group, an indenyl group, a fluorenyl group, a boratabenzene group, an aliphatic group, an aromatic group, a cyclic group, a combination of aliphatic and cyclic groups, an 'oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, A carbon group, a silicon group, a .germanium group, a tin group., a lead group, a boron group, an aluminum group, an inorganic group, aa organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; or a halide;
wherein each substituent on the substituted (X2) £5 independently an aliphatic group, an aromatic group, a cyclic group, a combination of ah'phatic and cyclic groups, an oxygen group, a sulfur group, a nitrogen group, a phosphorus group, an arsenic group, a carbon group, a silicon group, a germanium group, a tin group, a lead group, a boron group, ar. aluminum group, an inorganic group, an organometallic group, or a substituted derivative thereof, any one of which having from 1 to 20 carbon atoms; a halide; or hydrogen; and
wherein at least one subsn'tuent on (X2) is optionally a bridging group that connects (Xl)and(X2).
24. The process of Claim 20, wherein -flic piecontacted raetaliocene comprises a metallocene compound comprising:
bis(cyclopentadienyl)hafhiumdiehloride;
bis(cyclopentadienyl)ziiconium dichloride;
1 ,2-ethanediylbis(Tis- 1 -indenyl)di-n-butoxyhsrfhhnn;
1 ^-ethaiiediylbis(T}5-l-indenyl)dimethylziicoiiium;
3»3-pentanediylbis(T^s^^,6,7-teti^ydKHl4ndenyl)ha&\to^
methylpb^nylsilylbis(Tii^,5,6,7-tetral^dro-l-tndenyl)zirconium dichloride;
bis(n-butylcyclopentadienyl)bis(i-butylaniido)hafijiuni;
bis(l-?j-butyl-3-niethyl-cyGlopeatadienyl)ziiconiuin dichloride;
bis(7i-butylcyclopentadienyl)zirconium dichloride;
dimethylsilylbis(l-mdenyl)zircojiiuni dichloride;
octylphenylsilylbis( 1 -indenyl)ha&iinn dichloride;
-.
dimethylsilylbis(T| J-4,5,(5,7-tetrahydio-l-indenyl)2irGoniTmi dichloride; dimethylsilylbis(2-raethyl-l-indenyl)2irconiirm dichloride; 1 ,2-ethanediylbis(9-fIuorenyl)zbrconiuni dichloride; indenyl diethoxy titahium(TV) chloride;
(isopropylamidodimethylsilyl)cydopentadienyltitanium dichloride;
bis(pentamethylcyolopentadienyl}zirconium dichloride;
bis(indenyl) zirconium dichloride;
methyloctylsilylbis{9-fluorenyl)zirconiumdiehloride;
bis(2,7-di- bis-t 1 ^,N-diisopropy Iamino)boratabenzene]hydrido2irconium
trifluorbmethylsulfonate; • ,
dichloride; Tne zirconium dichloride;
-9-fl^ dichloride;
methyl^pentenyhnemylidpne(Ti5-cyclopentadienyl)(T\s-2,7-di-f-butyl-9-fluorenyl)zirconuun dichloride;
phenyl-3-butenylmethyUdene(Ti5^clDpentadie^ dichloride;
fluorenyl)zirconium dichloride;
dichloride; or
phenyl^-pentei^lmethylidCTe(Ti?- 25, The process of Claim 20, wherein the precontacted organoaluminum compound comprises an organoaluminum compound with the.following formula:
wherein (Xs) is a hydrocarbyl having from 2 to 20 carbon atoms; (X6) is an alkoxide or arytoxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride; and n is a number from 1 to 3, inclusive.
26. The process of Claim 20, wherein the precontacted organoaluminum compound
comprises triethylaluminum (TEA), trrprppylaluminum, diethylaluminum ethoxide,
tributylalumiiium, disobutylaluminum -hydride, triisobutylaluminum, diethylaluminum
chloride, or combinations thereof.
27. The process of Claim 20, further comprising contacting the precontacted mixture and
the acidic activator-support with at least one postcontacted organoaluminum compound with
the following formula:
wherein (X5) is a hydrocarbyl having from 1 to 20 carbon atoms; (X6) is an alkoxide or aryloxide, any one of which having from 1 to 20 carbon atoms, halide, or hydride; and n is a number from 1 tQ 3, inclusive, for a second period of time, to form a ppstcontacted mixture comprising at least one postcontaeted metallocene, at least one ppstcontacted organoaluminum compound, at least one ppstcontacted olefin or alkyne, and at least one postcontacted acidic activator-support.The process of Claim 20, wherein the precontacted olefin.or alkyne comprises a
compound having from 2 to 30 carbon atoms per molecule and having at least one carbon-
carbon double bond or at least one carbon-carbon triple bond.
28. The process of Claim 20, wherein the postcontacted acidic activator-support
comprises a solid oxide comprising silica, alumina, titania, zirconia, magnesia, boria, zinc
oxide, mixed oxides thereof, or mixtures thereof, wherein the inorganic oxide has been
treated with an electron-withdrawing anion comprising fluoride, chloride, bromide,
phosphate, triflate, bisulfate, sulfate, or combinations thereof.
29. The process of Claim 20, wherein, the postcontacted acidic activator-support
comprises fluorided silica-alumim.
30. The process of Claim 30, wherein the fluorided silica-alumina comprises from 5% to
95% by weight alumina and from 2% to 50%-by weight fluori.de ion, based on the weight of
the fluorided silica-alumina after drying but before calcining.
31. The process of Claim 30, wherein the fluorided silica-alumina comprises silica-
alumina having a pore volume greater than 0.5 cc/g, and a surface area greater than 100 rn2/g.
32. The process of Claim. .20, wherein the precontacted metallocene comprises
6is(indenyl)zitcdnium dichloride, &is(cyclopentadienyl)-zircomum dichloride, or bis(2,7-di-
/ert-butylfjuorenyl)-ethan-l^-diyl)zirconium{ry) dichloride; the precontacted
organoaluminum compound comprises trierhylalurninum; the precontacted olefin comprises
1-hexene; and the postcontacted acidic activator-support comprises fluorided silica-alumina.
33. The process of Claim 20, wherein the precontacted organoaluminum compound
comprises an aluroinacyclopentane, an alumraacyclopentadiene, an aluminacyclapentene, or
any combination thereof.
34. A catalyst composition comprising:
at least one precontacted metallocene;. at least one precontacted olefin or alkyne;
at least one postcontacted acidic activator-support; and at least one alurninacyclopentane.
36. A catalyst composition comprising:
at least one precontacted metallocene;
at least one precontacted olefin or alkyne;
at least one postcontacted acidic activator-support; and
at least one metallacyclopentane of a metallocene.
37. A resin made using a catalyst as defined in any one of claims 1 to 19.
38. A resin made using a catalyst as defined in any one of claims 35 to 36.

Documents:

7619-delnp-2006-abstract.pdf

7619-delnp-2006-assignment.pdf

7619-DELNP-2006-Claims-(12-10-2012).pdf

7619-delnp-2006-Claims-(29-04-2013).pdf

7619-delnp-2006-claims.pdf

7619-delnp-2006-Correspondence Others-(15-05-2012).pdf

7619-delnp-2006-Correspondence Others-(29-04-2013).pdf

7619-delnp-2006-Correspondence-others (22-05-2008).pdf

7619-DELNP-2006-Correspondence-Others-(12-10-2012).pdf

7619-delnp-2006-correspondence-others.pdf

7619-delnp-2006-description (complete).pdf

7619-delnp-2006-Form-1-(29-04-2013).pdf

7619-delnp-2006-form-1.pdf

7619-delnp-2006-form-13.pdf

7619-delnp-2006-Form-18 (22-05-2008).pdf

7619-delnp-2006-form-2.pdf

7619-delnp-2006-form-26.pdf

7619-DELNP-2006-Form-3-(12-10-2012).pdf

7619-delnp-2006-Form-3-(15-05-2012).pdf

7619-DELNP-2006-Form-3.pdf

7619-delnp-2006-Form-5-(29-04-2013).pdf

7619-DELNP-2006-Form-5.pdf

7619-DELNP-2006-GPA-(12-10-2012).pdf

7619-delnp-2006-GPA-(29-04-2013).pdf

7619-DELNP-2006-PCT-101.pdf

7619-delnp-2006-pct-220.pdf

7619-delnp-2006-pct-237.pdf

7619-delnp-2006-pct-304.pdf

7619-delnp-2006-pct-search report.pdf

7619-DELNP-2006-Petition-137-(12-10-2012).pdf


Patent Number 257923
Indian Patent Application Number 7619/DELNP/2006
PG Journal Number 47/2013
Publication Date 22-Nov-2013
Grant Date 20-Nov-2013
Date of Filing 15-Dec-2006
Name of Patentee CHEVRON PHILLIPS CHEMICAL COMPANY, LP
Applicant Address 10001 SIX PINES DRIVE, THE WOODLANDS, TX 77380, USA
Inventors:
# Inventor's Name Inventor's Address
1 JENSEN, MICHAEL 10329 SCAGGSVILLE ROAD, LAUREL, MD 20723, USA
2 MCDANIEL, MAX, P 1601 MELMART DRIVE, BARTLESVILLE, OK 74006, USA
3 MARTIN, JOEL, L 636 SE KENWOOD DRIVE, BARTLESVILLE, OK 74006, USA
4 YANG, QING 2917 MONTROSE DRIVE, BARTLESVILLE, OK 74006, USA
5 HAWLEY, GIL,R 1022 N. WYANDOTTE, DEWEY, OK 74029, USA
6 CRAIN, TONY 474 RD 30, NIOTAZE, KS 67355, USA
7 BENHAM, ELIZABETH 9310 KATIE GRACE CIRCLE, SPRING, TX 77379, USA
PCT International Classification Number C08F 10/00
PCT International Application Number PCT/US2005/022540
PCT International Filing date 2005-06-24
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/877,039 2004-06-25 U.S.A.