Title of Invention

A PROCESS FOR THE POLYMERIZATION OF AN OLEFIN MONOMER AND A CATALYST SYSTEM

Abstract The process for the polymerization of an olefm monomer, or of an olefm monomer and one or more comonomers, to produce a polymer, the process carried out in a polymerization reactor in the presence of a supported olefm polymerization catalyst system produced from catalyst components comprising: a support material component comprising one or more dehydrated support materials; a metallocene complex component comprising one or more metallocene complexes used in a total loading range of from 0.1 to 25 J.lmol of metallocene complex /gr~ of support material component; an activator component comprising one or more activators used in a range of molar ratios of total moles of activator to total moles of metallocene complex of from about 0.5 to a 2.5; where the catalyst system is used at a catalyst concentration in the range of from 0.01 to 6 moles of active catalyst/mole of monomer, and a catalyst efficiency results that is at least 2.4 x 10 g polymer/g mol catalyst/hour.
Full Text This invenη on relates to a process for the polymerizaη on of an olefin monomer, or of an olefin monomer and a supported olefin polymerizaη on catalyst system.
Recently there have been a number of advances in the producη on of polyolefin copolymers due to the introducη on of metallocene catalysts. Metallocene catalysts offer a number of advantages including improved acη vity compared to tradiη onal Ziegler catalysts under a given set of condiη ons. Also, metallocene catalysts are often described as being single-site in nature. Because of this single-site nature, the polyolefins produced with these catalysts are often very uniform in their molecular structure.
In order for metallocene catalysts to be commercially useful as supported catalysts in a gas phase, soluη on or slurry process, the catalysts employed preferably are highly acη ve. High producη vity of the catalyst in a polymerizaη on processes is desired to reduce catalyst costs and to avoid the expense of catalyst residue removal procedures. Thus, the catalyst residue in the polymer must be low enough that it can be left in the polymer without causing any undue problems to either the resin manufacturer, or to a party fabricaη ng arη cles from the resin, or to an ulη mate user of such fabricated arη cles. When a highly acη ve catalyst is used in a gas phase, soluη on or slurry process, the transiη on metal content of the polymer should be on the order of less than 1 part per million (ppm) of transiη on metal at a producη vity level of greater than 1,000,000 pounds of polymer per pound of transiη on metal.
One of the features of a gas phase polymerizaη on reactor is that the gas velocity in the reactor is limited to prevent excess carry-over of the solid parη cles from the fluid bed, which would happen if the velocity is set too high. If the gas velocity is set too

low, reactor fouling may occur due to fallout of polymer from the bed. Since the gas velocity is limited, the amount of heat which can be removed when operaη ng at a given set of condiη ons is also limited. The limitaη ons on heat removal place limitaη ons on the rate of producη vity for a given reactor. Attempts at improving the producη vity of a gas phase reactor by increasing the catalyst feed rate will often not be met with success because of the heat removal limitaη ons of the reactor.
A major improvement in reactor output and a parη al soluη on to the heat removal limitaη ons is described in U.S. 4,543,399; U.S. 5,352,749; EP 89691; WO 94/25495 and WO 94/28032, which are hereby incorporated by reference, where a volaη le liquid is fed to the reactor. The volaη le liquid evaporates in the hot fluidized bed to form a gas which mixes with the fluidizing gas. The evaporated liquid exits the top of the reactor as part of the recycle gas and passes through the heat exchange part of the recycle loop. The evaporated liquid condenses in the heat exchanger and is thei feed to the reactor as a volaη le liquid.
In pracη ce, in the gas phase commercial copolymers are made using monomer having 2 to 8 carbon atoms because of the lower concentraη ons possible in the reacto for alpha-oleflns with greater carbon numbers. Tradiη onal Ziegler catalysts are not parη cularly efficient or effecη ve at incorporaη ng the alpha-olefin comonomers having greater numbers of carbon atoms into the polymer. To date, highly acη ve and highly efficient supported metallocene catalysts, which do have high rates of alpha-olefin ;omonomer incorporaη on into the polymer, have not been demonstrated.
Up to now, supported metallocene catalysts useful for producing polyolefin η omopolymers and copolymers in gas phase and slurry processes have had reported catalyst efficiencies of less than 50,000,000 grams polymer/mole catalyst/hour for Zr based catalysts and 24,000,000 grams polymer/mole catalyst/hour for η based catalysts except when used with excepη onally high raη os of cocatalyst to catalyst. A variety of metallocene loadings and catalyst concentraη ons have been reported with no obvious trends. Indeed, due to the nonuniformity in the convenη ons used to report the data, and imprecision in the definiη ons of various terms in the disclosures, there appears to be little relaη onship between the use of various classes of metallocene complexes or any opη mal ranges for the various process variables employed.

where the catalyst system is used at a catalyst concentraη on in the range of from about 0.01 to about 6 moles of acη ve catalyst/mole of monomer, and a catalyst efficiency results that is at least 2.4 x 10? g polymer/g mol catalyst/hour.
In another embodiment, this invenη on provides a process for the polymerizaη on of an olefin monomer, or of an olefin monomer and one or more comonomers, to produce a polymer, the process carried out in a polymerizaη on reactor in the presence of a supported olefin polymerizaη on catalyst system produced from catalyst components comprising:
1) a support material component comprising one or more dehydrated support materials;
2) a metallocene complex component comprising one or more metallocene L2" complexes all of which have as a central metal η used in a total loading range of from about 0.1 to about 25 nmol of metallocene complex/gram of support material component;
3) an acη vator component comprising one or more acη vators used in a range of molar raη os of total moles of acη vator to total moles of metallocene complex of from about 0.5 to about 2.5;
where a catalyst efficiency results that is at least 0.5 x 10" g polymer/g catalyst/hour.
In another embodiment, this invenη on provides a process for the polymerizaη on of an olefin monomer, or of an olefin monomer and one or more comonomers, to produce a polymer, the process carried out in a polymerizaη on reactor in the presence of a supported olefin polymerizaη on catalyst system produced from catalyst components comprising:
1) a support material component comprising one or more dehydrated support materials;
2) a metallocene complex component comprising one or more metallocene complexes having as a central metal η in which the formal oxidaη on state is +2 used in a total loading range of from about 0.1 to about 25 2mol of metallocene complex/gram of support material component;
3) an acη vator component;

where a catalyst efficiency results that is at least 0.5 x 102 g polymer/g catalyst/hour.
J Also provided by this invenη on is a supported olefin polymerizaη on catalyst systerrVpiodtfced from catalyst components comprising:
1) a support material componentcomprising one or more dehydrated support materials;
2) a metallocene complex component; and
3) an acη vator component;
where the metallocene complex component is used in a loading range of from about 0.1 to about 25 2mol/gram of support material component, the cocatalyst or acη vator component is used in a range of molar raη os to the metallocene complex component of from about 0.5 to about 2.5, and, when the catalyst system is used in a reactor to polymerize one or more olefin monomers to produce a polymer, the catalyst system is used at a catalyst concentraη on in the range of about 0.01 to about 6 moles of acη ve catalyst/mole of monomer, and a catalyst efficiency results that is at least 2.4 x 10? g polymer mole of catalyst/hour.
An important aspect of the of this invenη on is that it provides a balance
of various catalyst system elements with polymerizaη on process elements, the results of
which is that the catalyst efficiency of the catalyst system is improved and can be
maximized. Accordingly, in one aspect of this invenη on, there is provided a process for
maximizing the efficiency of a catalyst system for the polymerizaη on of an olefin
monomer, or of an olefin monomer and one or more comonomers, to produce a
polymer, the process carried out in a polymerizaη on reactor in the presence of a
supported olefin polymerizaη on catalyst system produced from catalyst components
comprising? "
Vl) , a support material componentcomprising one or more dehydrated support materials;
2) a metallocene complex component; and
3) an acη vator component;
wherein the metallocene complex component is used in a loading range, in terms of mass of metallocene complex component relaη ve to the mass of support

material component, the acη vator component is used in a range of molar raη os of the , acη vator component to the metallocene complex component, and the catalyst system is used in a range of catalyst concentraη ons, in a balanced manner to maximize the 2 catalyst efficiency in terms of mass of polymer produced per mass of catalyst per hour
r
( In another embodiment this invenη on provides a catalyst system comprising: -""
a) a metallocene component comprising one or more metallocene complexes supported on individual metallocene supports or a common metallocene support; and
b) a cocatalyst component comprising one or more cocatalysts or acη vators supported on individual cocatalyst supports or a common cocatalyst support, where at least one of the cocatalysts or acη vators is a non-alumoxane nonionic cocatalyst or acη vator. /
DETAILED DESCRIPη ON ,
Table 1 gives data disclosed in various references, all of which are hereby incorporated by reference, related to the use of supported metallocene catalysts useful for producing polyolefin homo- and copolymers in gas phase, slurry and soluη on processes. Despite a variety of metallocene loadings ranging from 2 to 625 umol/gram silica, and cocatalyst/catalyst raη os from 1.2 to greater than 400, and in reactor catalyst concentraη ons (where the reactor is defined as the combined volumes of the polymerizaη on zone and freeboard for a fluid bed reactor or the combined volumes of the polymerizaη on zone and head space for a slurry or soluη on reactor) from 0.2 xlO" to more than 200 xlO6 mole catalyst/mole monomer, the reported catalyst efficiencies are less than 24.000,000 grams polymer/mole catalyst/hour, except when a very high catalyst loading and/or a very high raη o of cocatalyst to catalyst has been used. From these references no apparent trends of interrelaη onship between these factors is evident.



All references herein to elements or metals belonging to a certain Group refer to the Periodic Table of the Elements published and copyrighted by CRC Press, Inc., 1989. Also any reference to the Group or Groups shall be to the Group or Groups as reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups.
This invenη on provides a process for the polymerizaη on of an olefin monomer, or of an olefin monomer and one or more comonomers, to produce a polymer, the process carried out in a polymerizaη on reactor in the presence of a supported olefin polymerizaη on catalyst system produced from catalyst components comprising: 1) a metallocene complex component; 2) an acη vator component; and 3) a support material component.
Suitable metallocene complexes for use in the metallocene complex component of this invenη on include any compound or complex of a metal of Groups 3-10 of the Periodic Table of the Elements capable of being acη vated to olefin inserη on and polymerizaη on by the presence of an acη vator or through the use of a method of acη vaη on. These metallocene complexes may be weak catalysts prior to acη vaη on, or they may exhibit no catalyη c acη vity prior to acη vaη on. In the discussion herein, metallocene complexes subject to acη vaη on in the catalyst system of this invenη on may be referred to simply as catalysts. Examples include Group 10 diimine derivaη ves corresponding to the formula:

M*isNi(II)orPd(II);
K. is hydrocarbyl;
Ar* is an aryl group, especially 2,6-diisopropylphenyl, 2,6-dimethylphenyl, 2,6-di-t-butylphenyl, or 2,6-diphenylphenyl; and
T independently each occurrence is selected from the group consisη ng of hydrogen, C i .4 alkyl or phenyl, or two T groups together with the two carbon moieη es form a fused ring system, especially a 1,8-naphthanediyl group.

Certain of the foregoing catalysts are disclosed by M. Brookhart, et al„ in h Am. Chem. Soc. 118, 267-268 (1996) and J. Am. Chem. Soc. 117,6414-6415 (1995), as being acη ve polymerizaη on catalysts especially for polymerizaη on of a-olefins, either alone or in combinaη on with polar comonomers such as alkyl acrylates and alkyl methacrylates. In an embodiment of the present invenη on it has now been discovered that the foregoing catalysts also are effecη ve for use in the polymerizaη on of vinyl chloride monomer.
Addiη onal catalysts include derivaη ves of Group 3,4, 5, 6, 7, 8, or 9, or Lanthanide metals which are in the +2, +3, or +4 formal oxidaη on state. Preferred compounds include metal complexes containing from 1 to 3 2-bonded anionic or neutral ligand groups, which may be cyclic or noncyclic delocalized 2-bonded anionic ligand groups. Exemplary of such Ji-bonded anionic ligand groups are conjugated or nonconjugated. cyclic or noncyclic dienyl groups, allyl groups, boratabenzene groups, and arene groups. By the term "rc-bonded" is meant that the ligand group is bonded to the transiη on metal by means of a n bond.
Each atom in the delocalized rc-bonded group may independently be subsη tuted with a radical selected from the group consisη ng of hydrogen, halogen, hydrocarbyl, halohydrocarbyl, hydrocarbyl-subsη tuted metalloid radicals wherein the metalloid is selected from Group 14 of the Periodic Table of the Elements, and such hydrocarbyl-or hydrocarbyl-subsη tuted metalloid radicals further subsη tuted with a Group 15 or 16 heteroatom containing moiety. Included within the term "hydrocarbyl" are C|_20 straight, branched and cyclic alkyl radicals, C6_20 aromaη c radicals, C7.20 alkyl-subsη tuted aromaη c radicals, and C7.20 aryl-subsrituted alkyl radicals. In addiη on two or more such radicals may together form a fused ring system, a hydrogenated fused ring system, or a metallocycle with the metal. Suitable hydrocarbyl-subsη tuted organo-metalloid radicals include mono-, di- and tri-subsη tuted organometalloid radicals of Group 14 elements wherein each of the hydrocarbyl groups contains from 1 to 20 carbon atoms. Examples of suitable hydrocarbyl-subsη tuted organometalloid radicals include trimethylsilyl, triethylsilyl, ethyldimethylsilyl, methyldiethylsilyl, triphenylgermyl, and trimethylgermyl groups. Examples of Group 15 or 16 heteroatom containing moieη es include amine, phosphine, ether, or thioether moieη es or divalent derivaη ves

thereof, for example amide, phosphide, hydrocarbyloxy, hydrocarbylthio or thioether groups bonded to the transiη on metal or Lanthanide metal, and bonded to the hydrocarbyl group or to the hydrocarbyl-subsη tuted metalloid-containing group.
Examples of suitable anionic, delocalized 2-bonded groups include cyclopentadienyl, indenyl, fluorenyl, tetrahydroindenyl, tetrahydrofluorenyl, octahydrofluorenyl, pentadienyl, cyclohexadienyl, silacyclohexadienyl, allyl, dihydroanthracenyl, hexahydroanthracenyl, decahydroanthracenyl groups, and boratabenzene groups, as well as C\.\Q hydrocarbyl-subsη tuted or C\.\Q hydrocarbyl-subsη tuted silyl subsη tuted derivaη ves thereof. Preferred anionic delocalized rc-bonded groups are cyclopentadienyl, pentamethylcyclopentadienyl, tetramethylcyclopentadienyl, trimethylsilylcyclopentadienyl, indenyl, 2,3-dimethylindenyl. fluorenyl, 2-methylindenyl, 2-methyl-4-phenylindenyl, tetrahydrofluorenyl, octahydrofluorenyl, tetrahydroindenyl, cyclohexadienyl, and silacyclohexadienyl The boratabenzenes are anionic ligands which are boron containing analogues to benzene. They are previously known in the art having been described by G. Herberich, et al., in Organometallics. 14,1,471-480 (1995). Preferred boratabenzenes correspond to the formula:

wherein R" is selected from the group consisη ng of hydrocarbyl, silyl, or germyl, said R" having up to 20 nonhydrogen atoms.
A suitable class of catalysts are transiη on metal complexes corresponding to the formula:
LiMXmX"nX"p, or a dimer thereof
wherein:
L is an anionic, delocalized, n-bonded group that is bound to M, containing up to 50 nonhydrogen atoms, opη onally two L groups may be joined together forming a bridged structure, and further opη onally one L may be bound to X, or even further opη onally one L may be bound to X";

M is a metal of Group 4 of the Periodic Table of the Elements in the +2, +3 or +4 formal oxidaη on state;
X is an opη onal, divalent subsη tuent of up to 50 nonhydrogen atoms that together with L forms a metallocycle with M;
X" is an opη onal neutral Lewis base having up to 20 nonhydrogen atoms;
X" each occurrence is a monovalent, anionic moiety having up to 40 nonhydrogen atoms, opη onally, two X" groups may be covalently bound together forming a divalent dianionic moiety having both valences bound to M, or, opη onally 2 X" groups may be covalently bound together to form a neutral, conjugated or nonconjugated diene that is rt-bonded to M (whereupon M is in the +2 oxidaη on state), or further opη onally one or more X" and one or more X" groups may be bonded together thereby forming a moiety that is both covalently bound to M and coordinated thereto by means of Lewis base funcη onality;
I is 0, 1 or 2;
misO or 1;
n is a number from 0 to 3;
p is an integer from 0 to 3; and
the sum. 1+m+p, is equal to the formal oxidaη on state of M, except when 2 X" groups together form a neutral conjugated or nonconjugated diene that is rc-bonded to M, in which case the sum 1+m is equal to the formal oxidaη on state of M.
Preferred complexes include those containing either one or two L groups. The latter complexes include those containing a bridging group linking the two L groups. Preferred bridging groups are those corresponding to the formula (ER*2)X wherein E is silicon, germanium, η n, or carbon, R* independently each occurrence is hydrogen or a group selected from silyl, hydrocarbyl, hydrocarbyloxy and combinaη ons thereof, said R* having up to 30 carbon or silicon atoms, and x is 1 to 8. Preferably, R* independently each occurrence is methyl, ethyl, propyl, benzyl, tert-butyl, phenyl, methoxy, ethoxy or phenoxy. Preferably, x is 1 or 2.
Examples of the complexes containing two L groups are compounds corresponding to the formula:


wherein:
M is zirconium, zirconium or hafnium, preferably zirconium or hafnium, in the +2 or +4 formal oxidaη on state;
Ry in each occurrence independently is selected from the group consisη ng of hydrogen, hydrocarbyl, hydrocarbyloxy, silyl, germyl, cyano, halo and combinaη ons thereof, (especially, hydrocarbyloxysilyl, halocarbyl, and halohydrocarbyl) said R.3 having up to 20 nonhydrogen atoms, or adjacent R.3 groups together form a divalent derivaη ve (that is, a hydrocarbadiyl, siladiyl or germadiyl group) thereby forming a fused ring system, and
X" independently each occurrence is an anionic ligand group of up to 40 nonhydrogen atoms, or two X" groups together form a divalent anionic ligand group of up to 40 nonhydrogen atoms or together are a conjugated diene having from 4 to 30 nonhydrogen atoms forming a 7i-complex with M, whereupon M is in the +2 formal oxidaη on state, and
R*, E and x are as previously defined.
The foregoing metal complexes are especially suited for the preparaη on of polymers having stereoregular molecular structure. In such capacity it is preferred that the complex possesses Cs symmetry or possesses a chiral, stereorigid structure. Examples of the first type are compounds possessing different delocalized rc-bonded systems, such as one cyclopentadienyl group and one fluorenyl group. Similar systems based on η (IV) or Zr(IV) were disclosed for preparaη on of syndiotacη c olefin polymers in Ewen, et al., J. Am. Chem. Soc. 110, 6255-6256 (1980). Examples of chiral structures include rac bis-indenyl complexes. Similar systems based on η (IV) or

Zr(IV) were disclosed for preparaη on of isotacη c olefin polymers in Wild et al., J. Oreanomet. Chem.. 232, 233-47, (1982).
Exemplary bridged ligands containing two rc-bonded groups are: (dimethylsilyl-bis(cyclopentadienyl)), (methylphenylsilyl-bis(methylcyclopentadienyl)), (diphenylsilyl-bis(ethylcyclopentadienyl)), (dimethylsilyl-bis(t-butylcyclopentadienyl)),(dimethylsilyl-bis(tetramethylcyclopentadienyl)), (dimethylsilyl-bis(indenyl)), (dimethylsilyl-bis(tetrahydroindenyl)), (dimethylsilyl-bis(fluorenyl)), (dimethylsilyl-bis(tetrahydrofluorenyl)), (dimethylsilyl-bis(2-methyl-4-phenylindenyl)), (dimethylsilyl-bis(2-methylindenyl)), (dimethylsilyl-cyclopentadienyl-fluorenyl), (dimethylsilyl-cyclopentadienyl-octahydrofluorenyl), (dimethylsilyl-cyclopentadienyl-tetrahydrofluorenyl), (1,1,2,2-tetramethyl-l, 2-disilyl-bis-cyclopentadienyl), 1,2-bis(cyclopentadienyl)emane, and(isopropylidene-cyclopentadienyl-fluorenyl).
Preferred X" groups are selected from hydride, hydrocarbyl, hydrocarbyloxy, halo, amido, siloxy, phosphido, silyl, germyl, halohydrocarbyl, halosilyl, silylhydrocarbyl and aminohydrocarbyl groups, or two X" groups together form a divalent derivaη ve of a conjugated diene or else together they form a neutral, n-bonded, conjugated diene. Most preferred X" groups are Ci_20 hydrocarbyl groups.
A further class of metal complexes uη lized in the present invenη on corresponds to the preceding formula LiMXmX"nX"p, or a dimer thereof, wherein X is a divalent subsη tuent of up to 50 nonhydrogen atoms that together with L forms a metallocycle with M, or wherein one X" is bound to both L and M.
Preferred divalent X subsη tuents include groups containing up to 30 nonhydrogen atoms comprising at least one atom that is oxygen, sulfur, boron or a member of Group 14 of the Periodic Table of the Elements directly attached to the delocalized rc-bonded group, and a different atom, selected from the group consisη ng of nitrogen, phosphorus, oxygen or sulfur that is covalently bonded to M.
A preferred class of such Group 4 metal coordinaη on complexes used according to the present invenη on corresponds to the formula:


wherein:
M is η tanium or zirconium in the +2 or +4 formal oxidaη on state;
R3 in each occurrence independently is selected from the group consisη ng of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinaη ons thereof, said R3 having up to 20 nonhydrogen atoms, or adjacent R3 groups together form a divalent derivaη ve (that is, a hydrocarbadiyl, siladiyl or germadiyl group) thereby forming a fused ring system,
each X" is a hydride, hydrocarbyl, hydrocarbyloxy, siloxy, amido, phosphido, lalo or silyl group, said group having up to 20 nonhydrogen atoms, or two X" groups :ogether form a neutral 05.30 conjugated diene or a divalent derivaη ve thereof;
Y is -0-, -S-, -NR*-, -PR*-; and
Z is SiR*2, CR*2, SiR*2SiR*2, CR*2CR*2, CR*=CR*, CR*2SiR*2, or 3eR*2, wherein R* is as previously defined.
A further preferred class of Group 4 metal coordinaη on complexes used iccording to the present invenη on wherein one X" (illustrated by Z-Y") is bound to 30th L and M corresponds to the formula:

wherein:
M is η tanium in the +3 formal oxidaη on state;
R3 each occurrence is independently selected from the group consisη ng of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinaη ons thereof, said R3

having up to 20 nonhydrogen atoms, or adjacent R3 groups together form a divalent derivaη ve (that is a hydrocarbadiyl, siladiyl or germadiyl group) thereby forming a fused ring system;
each X" is a hydrocarbyl, hydrocarbyloxy, hydride, siloxy, amido, phosphido, halo or silyl group, said group having up to 20 nonhydrogen atoms;
Y" is -OR*, -SR\ -NR*2, -PR*2;
Z is SiR* 2,CR*2, SiR*2SiR*2, CR*2CR*2, CR*=CR\ CR*2SiR*2, or GeR*2, wherein R is as previously defined; and
n is a number from 0 to 3.
An especially preferred group of transiη on metal complexes for use in the catalysts of this invenη on are those disclosed in U.S. PatentJNo, 5,470,993. incorporated herein by reference, which correspond to the formula:

wherein:
M is η tanium or zirconium in the +2 formal oxidaη on state;
L is a group containing a cyclic, delocalized anionic, 7i-system through which the group is bound to M, and which group is also bound to Z;
Z is a moiety bound to M via a-bond, comprising boron, and the members of Group 14 of the Periodic Table of the Elements, and also comprising an element selected from the groups consisη ng of an element selected from the groups consisη ng of nitrogen, phosphorus, sulfur and oxygen, said moiety having up to 60 nonhydrogen atoms; and
X is a neutral, conjugated or nonconjugated diene, opη onally subsη tuted with one or more groups selected from hydrocarbyl or trimethylsilyl groups, said X having up to 40 carbon atoms and forming a 2-complex with M.
Illustraη ve Group 4 metal complexes that may be employed in the pracη ce of the present invenη on include:
cyclopentadienylη taniumtrimethyl, cyclopentadienylη taniumtriethyl, cyclopentadienylη taniumtriisopropyl,

cyclopentadienylη taniumtriphenyl,
methylcyclopentadienylη taniumtribenzyl,
pentamethylcyclopentadienylη tanium-2,4-dimethylpentadienyl,
cyclopentadienylη tanium-2,4-dimethylpentadienyl«triethylphosphine,
cyclopentadienylη tanium-2,4-dimethylpentadienyl»trimethylphosphine,
cyclopentadienylη taniumdimethylmethoxide, cyclopentadienylη taniumdimethylchloride,
pentamethylcyclopentadienylη taniumtrimethyl,
indenylη taniumtrimethyl,
2 -methy lindeny lη taniumtriethyl, 2-phenylindenylη taniumtripropyl,
3 -methylindenylη taniumtriphenyl,
tetrahydroindenylη taniumtribenzyl, tetramethylcyclopentadienylη taniumtriisopropyl, pentamethylcyclopentadienylη taniumtribenzyl, pentamethylcyclopentadienylη taniumdimethylmethoxide, pentamethylcyclopentadienylη taniumdimethylchloride, bis(r|5-2,4-dimethylpeiitadienyl)η tanium,
bis(r| 2 -3 -methy lpentadi enyl)η tanium»trimethy lphosphine,
bis(r\5-l ,5-bis(trimethylsilyl)pentadienyl)η tanium»triethylphosphine,
octahydrofluorenylη taniumtrimethyl,
tetrahydroindenylη taniumtrimethyl,
tetrahydrofluorenylη taniumtrimethyl,
(tert-butylamido)(l,l-dimethyl-2,3,4,9,10-ri-l,4,5,6,7,8-
hexahydronaphthalenyl)dimethylsilaneη taniumdimethyl, (tert-butylamido)( 1,1,2,3-tetramethyl-2,3,4,9,1 0-T]- 1,4,5,6,7,8-
hexahydronaphthalenyl)dimethylsilaneη taniumdimethyl, (cyclohexy lamido)(tetramethyl-ri5 -cyclopentadienyl)dimethylsilaneη tanium dibenzyl, (tert-butylamido)(tetramethyl-ri5-cyclopentadienyl)dimethylsilaneη tamum dimethyl, (tert-butylamido)(tetramethyl-η 5-cyclopentadienyl)-l,2-ethanediylη tanium dimethyl, (tert-butylamidoXtetramethyl-η 5 -indenyl)dimethylsilaneη tanium dimethyl, (tert-butylamido)(tetramethyl-ri5-cyclopentadienyl)dimethylsilane η tanium (III) 2-(dimethylamino)benzyl,

(tert-butylamido)(tetramethyl-η 5-cyclopentadienyl)dimethylsilanetitanium(III)aUyl, (isopropylamido)(tetramethyl-η 5 -cyclopentadienyl)dimethylsilanetitanium (III) 2,4-dimethylpentadienyl,
(tert-butylamido)(tetramethyl-η 5-cyclopentadienyl)dimethylsilanetitanium(II) 1,4-diphenyl-l .3-butadiene,
(tert-butylamido)(tetramethyl-,η 5-Cyclopentadienyl)dimethyrsilanetitanium(II)
1,3-pentadiene.
(tert-butylamido)(2-methylindenyl)dimethylsilanetitanium (II) 1,4-diphenyl-1,3-
butadiene,
(cyclodocedylamindo)(2-methylindenyl)dimethylsilanetitanium(II)2,4-hexadiene,
(tert-butylamido)(2-methylindenyl)dimethylsilanetitanium (IV) 2,3-dimethyl-1,3-
butadiene,
(anilido)(2-methylindenyl)dimethylsilanetitaiiium (IV) isoprene,
(ethylamido)(2-methylindenyl)dimethylsilanetitanium(III)2-(dimethylamino)ben2yl,
(tert-butylamido)(2,3-dimethylindenyl)dimethylsilanetitanium(IV)
2,3-dimethyl-1.3-butadiene,
(cyclohexylamido)(2,3-dimethylindenyl)dimethylsilanetitanium(III)
2-(dimethylamino)benzyl, (tert-butylamido)(2,3-dimethylindenyl)dimethylsilanetitanium
(IV) dimethyl(methylamido)(2,3-dimethylindenyl)dimethylsilanetitanium (IV) dibenzyl
(anilido)(2,3-dimethylindenyl)dimethylsilanetitaniuin (IV) 1,3-butadiene,
(tert-butylamido)(2,3-dimethylindenyl)dimethylsilanetitanium (II) 1,3-pentadiene,
(tert-butylamido)(2,3-dimethylindenyl)dimethylsilanetitanium (II) 1,4-diphenyl-l ,3-
butadiene,
(anilido)(2-methylindenyl)dimethylsilanetitanium (II) 1,3-pentadiene,
(tert-butylamido)(2-methylindenyl)dimethylsilanetitanium (IV) dimethyl,
(tert-butylamido)(2-methylindenyl)dimethylsilanetitanium(III)
2 -(dimethy lamino)benzyl,
(tert-butylamido)(2-methyl-4-phenylindenyl)dimethylsilanetitanium (II) 1,4-diphenyl-
1,3-butadiene,
(tert-butylamido)(2-methyl-4-phenylindenyl)dimethylsilanetitanium (II) 1,3-pentadiene,
(cyclohexylamido)(2-methyl-4-phenylindenyl)dimethylsilanetitanium(II)2,4-hexadiene,

*
(tert-butylamido)(tetramethyl-ri5-cyclopeiitadienyl)dimethylsilaneη taniiim(IV) 1,3-butadiene,
(tert-butylamido)(tetramethyl-η 5.cyclopentadienyl)dimethylsilaneη tanium(III) 2-(dimethylamino)benzyl
(tert-butylamido)(tetramethyl-ri5-cyclopentadienyl)dimethylsilaneη tanium(IV) isoprene.
(tert-pentylamido)(tetramethyl-r| 5 -cyclopentadienyl)dimethylsilaneη tanium (II) 1,4-dibenzyl-1.3 -butadiene,
(tert-butylamido)(tetramethyl-η 5-cyclopentadienyl)dimethylsilaneη tanium(II) 2,4-hexadiene,
(tert-butylamido)(tetramethyl-η 5-cyclopentadienyl)dimethylsilaneη tanium(II) 3-methyl-1,3-pentadiene,
(tert-butylamido)(2,4Kiimethylpentadienyl)dimethylsilaneη taniumdimethyl, (tert-butylamido)(6,6-dimethylcyclohexadienyl)dimethylsilaneη taniumdimethyl, (tert-octylamido)( 1,1 -dimethyl-2,3,4,9,10-r(-1,4,5,6,7,8-hexahydronaphthalen-4-yl)dimethylsilanentaniumdimethyl, (anilido)( 1,1,2.3-tetramethyl-2,3,4,9,1 Q-r\-1,4,5,6,7,8-hexahydronaphthaIen-4-yl)dimethylsilaneη taniumdimethyl
(tert-butylamido)(tetramethyl-,η 5-cyclopentadienyl)methylphenyl-silaneη tanium(IV) dimethyl,
(tert-butylamido)(tetramethyl-η 5-cyclopentadienyl)methylphenyl-silaneη tanium(II) 1,4-diphenyl-1.3-butadiene,
l-(tert-butylamido)-2-(tetramethyl-r|5-cyclopentadienyl)ethanediyl-η tanium(IV) dimethyl,
1 -(tert-butylamido)-2-(tetramethyl-η 5-cyclopentadienyl)ethanediyl-η tanium (II) 1,4-diphenyl-1,3-butadiene, l-(dimethylamino)-2-(tetramethyl-η 5-cyclopentadienyl)ethanediyl-η tanium(III)
dimethyl,
1 -(dimethylamino)-2-(tetramethyl-η 5-cyclopentadienyl)ethanediyl-η tanium (III) diallyl,
l-(dime%laniino)-2-(tetramethyl-η 5-cyclopentadienyl)ethanediyl-η tanium(III)
dibenzyl,

l l-(diisopropylamino)-2-(tetramethyl-r|5-cyclopentadienyl)ethanediyl-η tanium(III) dimethyl,
l-(methylphenylamino)-2-(tetramethyl-ri5-cyclopentadienyl)ethanediyl-η tanium(III) dimethyl,
(dimethylaminoXtetramethyl-ri2-cyclopentadienyOdimethylsilylη tanium (III) dimethyl,
(diethylamino)(tetramethyl-r|5-cyclopentadienyl)dimethylsilylη tanium(III)diallyl,
(dimethylaminoXtetramethyl-η 5-cyclopentadienyl)dimethylsilylη tanium(III)dibenzyl,
(diisobutylamino)(tetramethyl-r|2-cyclopentadienyl)dimethylsilyl-η tanium(III)
dimethyl,
(diisopropylamino)(tetramethyl-r|5-cyclopentadienyl)dimethylsilyl-η tanium(III)
methylphenyl,
(methylphenylamino)(tetramethyl-2-cyclopentadienyl)dimethylsilyl-η tanium(III)
dimethyl,
(1 -methylethoxy)(tetramethyl-r|5-cyclopentadienyl)dimethylsilane-η tanium (III)
dimethyl,
I -(dimethylamino)-2-(tetramethyl-T\5-cyclopentadienyl)-1,1,2,2-
tetramethyldisilylη tanium (III) dimethyl, 1 -(dimethylamino)-2-(tetramethyl-T|5-cyclopentadienyl)-1,1,2,2-
tetramethyldisilylη tanium (III) diallyl, 1 -(diethylamino)-2-(tetramethyl-r|5-cyclopeiitadienyl)-1,1,2,2-
tetramethyldisilylη tanium (III) diben2yl, 1 -(diisobutylamino)-2-(tetramethyl-η 5-cyclopentadienyl)-1,1,2,2-
tetramethyldisilylη tanium (III) dimethyl, 1 -(diisopropylamino)-2-(tetramethyl-T|5-cyclopentadienyl)-l, 1,2,2-
tetramethyldisilylη tanium (III) dimethyl, 1 -(methylphenylamino)-2-(tetramethyl-η 5-cyclopentadienyl)-1,1,2,2-
tetramethyldisilylη tanium (III) dimethyl,
1 -(diethylamino)-2-(2,3-dimethyl-η 5-indenyl)ethanediylη tanium (III) dimethyl, 1 -(dimethylamino)-2-(2-methyl-η 5-indenvnethanediv1η tanium (Uft diallvl.

1 -(dimethylamino)-2-(2,3,4,6-tetramethyl-ri5-indenyl)ethanediylη tanium (III) dibenzyl,
1 -(diisobutylamino)-2-(r|5-indenyl)ethanediylη tanium (III) dimethyl,
1 -(diisopropylamino)-2-(ri5-cyclopentadienyl)ethanediylη tanium (III) dimethyl,
1 -(methylphenylamino)-2-(r|5-tetrahydroindenyl)ethanediylη tanium (III) dimethyl,
(dimethylaminoX r|5-tetrahydrofluorenyl)dimemylsilylη tanium (III) dimethyl,
(diethylaminoX r|5-octahydrofluorenyl)dimethylsilylη tanium (III) diallyl,
(dimethylamino)( 2,3,4,6-tetramethyl-η 5-indenyl)dimethylsilylη tanium (III) dibenzyl,
(diisobutylamino)(2,3,4,6-tetramethyl-η 5-indenyl)dimethylsilyl-η tanium (III) dimethyl,
(diisopropylamino)(2,3,4,6-tetramethyl-η 5-indenyl)dimethylsilyl-η tanium (III) dimethyl,
(methylphenylamino)( 2,3,4,6-tetramethyl-ri 5 -indenyl)dimethylsilyl-η tanium (III)
dimethyl,
(1 -methylethoxy)(2,3,4,6-tetramethyl-η 5-indenyl)dimethylsilaneη taniiim (III) dimethyl,
1 -(dimethylamino)-2-(2,3,4,6-tetramethyl-ri5-indenyl)-1,1,2,2-
tetramethyldisilylη tanium (III) dimethyl, 1 -(dimethylamino)-2-(2,3,4,6-tetramethyl-rj2-indenyl)-1,1,2,2-
tetramethyldisilylη tanium (III) diallyl, 1 -(diethylamino)-2-(2,3,4,6-tetramethyl-T]5-indenyl)-1,1,2,2-
tetramethyldisilylη tanium (III) dibenzyl, 1 -(diisobutylamino)-2-(2,3,4,6-tetramethyl-r|5-indenyl)-1,1,2,2-
tetramethyldisilylη tanium (III) dimethyl, 1 -(diisopropylamino)-2-(2,3,4,6-tetramethyl-T|5-indenyl)-l, 1,2,2-
tetramethyldisilylη tanium (III) dimethyl, and l-(methylphenylamino)-2-(2,3,4,6-tetramethyl-η 5-indenyl)-l,1,2,2-tetramethyldisilylη tanium (HI) dimethyl.
Complexes containing two L groups including bridged complexes suitable for use in the present invenη on include:
bis(cyclopentadienyl)zirconiumdimethyl, bis(butylcyclopentadienyl)zirconium dibenzyl,
bis(cyclopentadienyl)zirconium methyl benzyl, bis(cyclopentadienyl)zirconium methyl phenyl, bis(methylcyclopentadienyl)zirconiumdiphenyl, bis(cyclopentadienyl)η tanium-allyl,

bis(butylcyclopentadienyl)zirconiummethylmethoxide,
bis(cyclopentadienyl)zirconiummethylchloride,
bis(pentamethylcyclopentadienyl)zircoη iumdimethyl,
bis(pentamethylcyclopentadienyl)η taniumdimethyl,
bis(indenyl)zirconiumdimethyl,
indenylfluorenylzirconiumdimethyl,
bis(2-phenylindenyl)zirconiummethyl(2-(dimethylamino)benzyl),
bis(indenyl)zirconiummethyltrimethylsilyl,
bis(tetrahydroindenyl)zirconiummethyltrimethylsilyl,
bis(trimethylsilylcyclopeη tadienyl)zirconiummethylbenzyl,
bis(pentamethyIcyclopentadienyl)zirconiumdibenzyI,
bis(pentamethylcyclopentadienyl)zirconiummethylmethoxide,
bis(tetramethylcyclopentadienyl)zirconiummethylchloride,
bis(methy lethylcy clopentadienyl)zirconiumdimethyl,
bis(ethylbutylcyclopentadienyl)zirconiumdibenzyl,
bis(t-butylcyclopentadienyl)zirconiumdimethyl,
bis(ethyltetramethylcyclopentadienyl)zirconiumdimethyl,
bis(methylpropy lcyclopentadienyl)zirconium dibenzy 1,
bis(bis(trimethylsilyl)cyclopentadienyl)zirconiumdibenzyl,
dimethylsilyl-bis(cyclopentadienyl)zirconiumdimethyl,
dimethylsilyl-bis(tetramethylcyclopentadienyl)η taiiium-(III)allyl
dimethylsilyl-bis(t-butylcyclopentadienyl)zirconiumdichloride, dimethylsilyl-bis(n-
butylcyclopentadienyl)zirconinmdichloride,
methylene-bis(tetramethylcyclopentadienyl)η tanium(III)2-(dimethylamino)benzyl,
methylene-bis(n-butylcyclopentadienyl)η tanium(III)2-(dimethylaminomethyl)phenyl,
dimethylsilyl-bis(indenyl)zirconiumbenzylchloride,
dimethylsilyl-bis(2-methylindenyl)zirconiumdimethyl,
dimethylsilyl-bis(2-methyl-4-phenylindenyl)zirconiumdimethyl,
dimethylsilyl-bis(2-methylindenyl)zirconium(II) 1,4-diphenyl-l ,3-butadiene,
dimethylsilyl-bis(2-methyl-4-phenylindenyl)zirconium (II) 1,4-diphenyl-1,3-butadiene,
dimethylsilyl-bis(tetrahydroindenyl)zirconium(II) 1,4-diphenyl-l ,3-butadiene,

dimemylsilyl-bis(fluorenyl)zirconiummethylchloride, dimethylsilyl-bis(tetrahydrofluorenyl)zirconiumbis(trimethylsilylinethyl), (isopropylidene)(cyclopentadienyl)(fluorenyl)zirconiumdibenzyl, and dimethylsilyl(tetramethylcyclopentadienyl)(fluorenyl)zirconium dimethyl.
(NKia2imethylethyl)-l,l-dimethyl-l-((l,2,3,3a,7a-η ).3-(l-pyrrolidinyl)-lH-inden-1 -yl)silanaminato(2-)-N)dimethylη tanium
(N-( 1,1 -dimethylethyl)-1,1 -dimethyl-1 -((1,2,3,3a,7a-r|)-3-( 1 -piperidinyl>l H-inden-1 -yt)silanaminato(2-)-N)dimethylη tanium
((2-(dimethylamino)phenyl)methyl)( 1,1 -dimethyl-N-phenyl-1 -((1,2,3,3a,7a-rj)-3 -(1 -pyrrolidinyl)-1 H-inden-1 -yl)silanaminato(2-)-N)η tanium
(N-( 1,1-dimethylethyl)-1,1-dimethyl-1-((1,2,3,3a, 7a-ri)-3-( 1-pyrrolidinyl)-l H-inden-1 -yl)silanaminato(2-)-N)(( 1,2,3,4-r|)-2,4-hexadiene)η tanium
(1,1" -(r|4-1,3 -butadiene-1,4-diyl)bis(benzene))(N-( 1,1 -dimethylethyl)-1,1-dimethyl-1 -((1,2.3,3a,7a-n,)-3-( 1 -pyrrolidinyl)-1 H-inden- l-yl)silanaminato(2-)-N)η tanium
((2-(dimethylamino)phenyl)methyl)(N-( 1,1 -dimethylethyl)-1,1 -dimethyl-1 -((1,2,3,3a,7a-r| )-3-( 1 -pyrrolidinyl)-1 H-inden-1 -yl)silanaminato(2-)-N)η tanium
(N-cyclohexyl-1,1 -dimethyl-1 -((1,2,3,3a, 7a-n>5-phenyl-3-( 1 -pyrrolidinyl)-1H-inden-1 -yl)silanaminato(2-)-N)dimethylη tanium
(N-( 1,1 -dimethylethyl)-1,1 -dimethyl-1 -((1,2,3,3a, 7a-η )-3-(dimethylamino)-1H-inden-1 -yl)silanaminato(2-)-N)dimethylη tanium
(N-( 1,1 -dimethylethyl)-1,1 -dimethyl-1 -((1,2,3,3a,7a-"n)-3-methoxy-1 H-inden-1 -yl)silanaminato (N-(l,l-dimethylethyl)-2-((l,2,3,3a,7a-ri)-2-methyl-3-(l-pyrrolidinyl)-lH-inden-1 -yl)-ethanaminato(2-)-N)dimethylη tanium
(1,1 "-(n4-1,3-butadiene-1,4-diyl)bis(benzene))(N-( 1,1 -dimethylethyl)-1,1-dimethyl-1 -((1,2.3,4,5-η )-2,4,5-trimethyl-3-( 1 -pyrrolidinyl)-2,4-cyclopentadien-1 -yl)silanaminato
■J
Especially preferred bis-Cp complexes for use in the catalysts useful in this lvenη on are the bridged bis-Cp complexes of EP 676,421 which correspond to the formula:
wherein
Cp", Cp2 are independently a subsη tuted or unsubsη tuted indenyl or hydrogenated indenyl group;
Y is a univalent anionic ligand, or Y2 is a diene;
M is zirconium, η tanium or hafnium; and
Z is a bridging group comprising an alkylene group having 1 to 20 carbon atoms or a dialkylsilyl or dialkylgermyl group, or alkylphosphine or alkylamine radical.
Another class of preferred metal complexes for use in the present invenη on correspond to the formula (I);

where M is η tanium, zirconium or hafnium in the +2, +3 or +4 formal oxidaη on state;
R is an aryl ligand or a halo-, silyl-, alkyl-, cycloalkyl-, dihydrocarbylamino-, hydrocarbyloxy-, or hydrocarbyleneamino-, subsη tuted derivaη ve thereof, said R" having from 6 to 40 nonhydrogen atoms;
Z is a divalent moiety, or a moiety comprising one cr-bond and a neutral two electron pair able to form a coordinate-covalent bond to M, said Z comprising boron, or a member of Group 14 of the Periodic Table of the Elements, and also comprising nitrogen, phosphorus, sulfur or oxygen;

X is a monovalent anionic ligand group having up to 60 atoms exclusive of the class of ligands that are cyclic, delocalized, ft-bound ligand groups;
X" independently each occurrence is a neutral Lewis base ligaη ng compound having up to 20 atoms;
X" is a divalent anionic ligand group having up to 60 atoms;
p is zero, 1, 2, or 3;
q is zero, 1 or 2; and
r is zero or 1.
The above complexes may exist in pure form or as a mixture with other complexes, in the form of a solvated adduct, opη onally in a solvent, especially an organic liquid, as well as in the form of a dimer or chelated derivaη ve thereof, wherein the chelaη ng agent is an organic material.
Another class of preferred metal complexes for use in the present invenη on correspond to the formula:

where M is a metal from one of Groups 3 to 13 of the Periodic Table of the Elements, the lanthanides or acη nides, which is in the +2, +3 or +4 formal oxidaη on state and which is rc-bonded to one cyclopentadienyl group (Cp) which is a cyclic, delocalized, n-bound ligand group having 5 subsη tuents: RA; (RB)J-T where j is zero, 1 or 2; RC; R2 and Z; where R2, RB, RC and RD WQ R groups; and where
T is a heteroatom which is covalently bonded to the Cp ring, and to RB when j is 1 or 2, and when j is 0, T is F, CI, Br, or I; when j is 1, T is O or S, or N or P and RB has a double bond to T; when j is 2, T is N or P; and where
RB independently each occurrence is hydrogen, or, is a group having from 1 to 80 nonhydrogen atoms which is hydrocarbyl, hydrocarbylsilyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilylhydrocarbyl, hydrocarbylamino, di(hydrocarbyl)amino, hydrocarbyloxy, each RB opη onally being subsη tuted with one or more groups which

independently each occurrence is hydrocarbyloxy, hydrocarbylsiloxy, hydrocarbylsilylamino, di(hydrocarbylsilyl)amino, hydrocarbylamino, di(hydrocarbyl)amino, di(hydrocarbyl)phosphino, hydrocarbylsulfldo, hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilyl or hydrocarbylsilylhydrocarbyl having from 1 to 20 nonhydrogen atoms, or a noninterfering group having from 1 to 20 nonhydrogen atoms; and each of R2, R2 and RD is hydrogen, or is a group having from 1 to 80 nonhydrogen atoms which is hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylammo-subsη tuted hydrocarbyl, hydrocarbylsilyl,
hydrocarbylsilylhydrocarbyl, each K\ RC or RD opη onally being subsη tuted with one or more groups which independently each occurrence is hydrocarbyloxy, hydrocarbylsiloxy, hydrocarbylsilylamino, di(hydrocarbylsilyl)amino, hydrocarbylamino, di(hydrocarbynamino, di(hydrocarbyl)phosphino, hydrocarbylsulfldo, hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilyl or hydrocarbylsilylhydrocarbyl having from 1 to 20 nonhydrogen atoms, or a noninterfering group having from 1 to 20 nonhydrogen atoms; or, opη onally, two or more of R\ RB, RC arui RD are COvalently linked with each other to form one or more fused rings or ring systems having from 1 to 80 nonhydrogen atoms for each R group, the one or more fused rings or ring systems being unsubsη tuted or subsη tuted with one or more groups which independently each occurrence are hydrocarbyloxy, hydrocarbylsiloxy, hydrocarbylsilylamino, di(hydrocarbylsilyl)amino, hydrocarbylamino, di(hydrocarbyl )amino, di(hydrocarbyl)phosphino, hydrocarbylsulfldo, hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamiBO-subsη tuted hydrocarbyl, hydrocarbylsilyl or hydrocarbylsilylhydrocarbyl having from 1 to 20 nonhydrogen atoms, or a noninterfering group having from 1 to 20 nonhydrogen atoms;
Z is a divalent moiety bound to both Cp and M via a-bonds, where Z comprises boron, or a member of Group 14 of the Periodic Table of the Elements, and also comprises nitrogen, phosphorus, sulfur or oxygen;

X is an anionic or dianionic ligand group having up to 60 atoms exclusive of the ass of ligands that are cyclic, delocalized, JI-bound ligand groups;
X" independently each occurrence is a neutral Lewis base ligaη ng compound iving up to 20 atoms;
p is zero. 1 or 2, and is two less than the formal oxidaη on state of M, when X is l anionic ligand; when X is a dianionic ligand group, p is 1; and
q is zero. 1 or 2.
Another class of preferred metal complexes for use in the present invenη on 2responding to the formula:

where M is a metal from one of Groups 3 to 13 of the Periodic Table of the ilements, the lanthanides or acη nides, which is in the +2, +3 or +4 formal oxidaη on tate and which is 7r-bonded to one cyclopentadienyl group (Cp) which is a cyclic, lelocalized, rc-bound ligand group having 5 subsη tuents: (R2)j-T where j is zero, 1 or >; RB; Rc ; RD and Z; where RA, RB, Rc and RD are R groups; and where
T is a heteroatom which is covalently bonded to the Cp ring, and to RA when j s 1 or 2, and when j is 0, T is F, CI, Br, or I; when j is 1, T is O or S, or N or P and RA las a double bond to T; when j is 2, T is N or P; and where
RA independently each occurrence is hydrogen, or, is a group having from 1 to 80 nonhydrogen atoms which is hydrocarbyl, hydrocarbylsilyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilylhydrocarbyl, hydrocarbylamino, di(hydrocarbyl)amino, hydrocarbyloxy. each RA opη onally being subsη tuted with one or more groups which independently each occurrence is hydrocarbyloxy, hydrocarbylsiloxy, hydrocarbylsilylamino, di(hydrocarbylsilyl)amino, hydrocarbylamino, di(hydrocarbyl)amino, di(hydrocarbyl)phosphino, hydrocarbylsulfido, hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilyl or

hydrocarbylsilylhydrocarbyl having from 1 to 20 nonhydrogen atoms, or a noninterfering group having from 1 to 20 nonhydrogen atoms; and each of R2, RC and RD is hydrogen, or is a group having from 1 to 80 nonhydrogen atoms which is hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilyl,
hydrocarbylsilylhydrocarbyl, each RB, R2 or R2 opη onally being subsη tuted with one or more groups which independently each occurrence is hydrocarbyloxy, hydrocarbylsiloxy, hydrocarbylsilylamino, di(hydrocarbylsilyl)amino, hydrocarbylamino, di(hydrocarbyl)amino, di(hydrocarbyl)phosphino, hydrocarbylsulfido, hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilyl or hydrocarbylsilylhydrocarbyl having from 1 to 20 nonhydrogen atoms, or a noninterfering group having from 1 to 20 nonhydrogen atoms; or, opη onally, two or more of R\ R2, RC and RD are covalently linked with each other to form one or more fused rings or ring systems having from 1 to 80 nonhydrogen atoms for each R group, the one or more fused rings or ring systems being unsubsη tuted or subsη tuted with one or more groups which independently each occurrence are hydrocarbyloxy, hydrocarbylsiloxy, hydrocarbylsilylamino, di(hydrocarbylsilyl)amino, hydrocarbylamino, di(hydrocarbyl)amino, di(hydrocarbyl)phosphino, hydrocarbylsulfido, hydrocarbyl, halo-subsη tuted hydrocarbyl, hydrocarbyloxy-subsη tuted hydrocarbyl, hydrocarbylamino-subsη tuted hydrocarbyl, hydrocarbylsilyl or hydrocarbylsilylhydrocarbyl having from 1 to 20 nonhydrogen atoms, or a noninterfering group having from 1 to 20 nonhydrogen atoms;
Z is a divalent moiety bound to both Cp and M via c-bonds, where Z comprises boron, or a member of Group 14 of the Periodic Table of the Elements, and also comprises nitrogen, phosphorus, sulfur or oxygen;
X is an anionic or dianionic ligand group having up to 60 atoms exclusive of the class of ligands that are cyclic, delocalized, rc-bound ligand groups;
X" independently each occurrence is a neutral Lewis base ligaη ng compound having up to 20 atoms;

p is zero, 1 or 2, and is two less than the formal oxidaη on state of M, when X is an anionic ligand; when X is a dianionic ligand group, p is 1; and
q is zero, 1 or 2.
Constrained geometry metal complexes and methods for their preparaη on are disclosed in U.S. Applicaη on Serial No. 545,403, filed July 3,1990 (EP-A-416,815); U.S. Applicaη on Serial No. 547,718, filed July 3, 1990 (EP-A-468,651); U.S. Applicaη on Serial No. 702,475, filed May 20, 1991 (EP-A-514,828); U.S. Applicaη on Serial No. 876.268, filed May 1, 1992 (EP-A-520,732); and U.S. Applicaη on Serial No. 8,003, filed January 21, 1993 (WO 93/19104), as well as U.S.-A-5,055,4382LJ.S.-A-5,057,475; U.S.-A-5,096,867; U.S::A-5,064J,802aJ.S.-A-5,132,380; and WO 95/00526. The teachings of all of the foregoing patents or the corresponding U..5L patent applicaη ons are hereby incorporated by reference.
The metallocene complex component may be produced with a single metallocene complex, or, in alternaη ve embodiment, it may be produced with two or more metallocene complexes, or it may be produced with at least one metallocene complex and at least one nonmetallocene complex..,
Other catalysts, especially catalysts containing other Group 4 metals, will, of course, be apparent to those skilled in the art.
The supported olefin polymerizaη on catalyst system comprises an acη vator component which is used to acη vate the metallocene complex component of the catalyst system. In a preferred embodiment of this invenη on, the acη vator component comprises a cocatalyst, especially an acη vaη ng cocatalyst.
Alternaη vely, in another embodiment, the complexes are rendered catalyη cally acη ve by the use of an acη vaη ng technique or method.
Suitable acη vaη ng cocatalysts for use herein include polymeric or oligomeric alumoxanes, especially methylalumoxane, triisobutyl aluminum- modified methylalumoxane, or diisobutylalumoxane; strong Lewis acids, such as C1.30 hydrocarbyl subsη tuted Group 13 compounds, especially tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron- compounds and halogenated derivaη ves thereof, having from 1 to 10 carbons in each hydrocarbyl or halogenated hydrocarbyl group, especially tris(pentafluorophenyl)borane; and nonpolymeric, inert, compaη ble, noncoordinaη ng, ion forming compounds (including the use of such compounds under oxidizing condiη ons). A suitable acη vaη ng technique is bulk electrolysis (explained in more detail

hereinafter). Combinaη ons of the foregoing acη vaη ng cocatalysts and techniques may also be employed if desired. The foregoing acη vaη ng cocatalysts and acη vaη ng techniques have been previously taught with respect to different metal complexes in the following references: EP-A-277,003; U.S.-A-5,153,157; U.S.-A-5,064,802; EP-A-468,651 (equivalent to U. S. Serial No. 07/547,718); EP-A-520,732 (equivalent to U. S. Serial No. 07/876,268); and U.S.-A-5,350,723; teachings of which are hereby incorporated by reference.
Suitable nonpolymeric, inert, compaη ble, noncoordinaη ng, ion forming compounds useful as cocatalysts in one embodiment of the present invenη on comprise a caη on which is a Bronsted acid capable of donaη ng a proton, and a compaη ble, noncoordinaη ng, anion, A". Preferred anions are those containing a single coordinaη on complex comprising a charge-bearing metal or metalloid core which anion is capable of balancing the charge of the acη ve catalyst species (the metal caη on) which is formed when the two components are combined. Also, said anion can be displaced by olefinic, diolefinic and acetylenically unsaturated compounds or other neutral Lewis bases such as ethers or nitriles. Suitable metals include, but are not limited to, aluminum, gold and plaη num. Suitable metalloids include, but are not limited to, boron, phosphorus, and silicon. Compounds containing anions which comprise coordinaη on complexes containing a single metal or metalloid atom are well known and many, parη cularly such compounds containing a single boron atom in the anion porη on, are available commercially.
Preferably such cocatalysts may be represented by the following general formula:
wherein:
L* is a neutral Lewis base;
(L*-H)+ is a Bronsted acid;
A2_ is a noncoordinaη ng, compaη ble anion having a charge of d-, and
d is an integer from 1 to 3.
More preferably d is one, that is, Ad- ISA".

Highly preferably, A" corresponds to the formula: [BQ4]" wherein:
B is boron in the +3 formal oxidaη on state; and
Q independently each occurrence is selected from hydride, dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, halocarbyl, and halo-subsη tuted-hydrocarbyl radicals, said Q having up to 20 carbons with the proviso that in not more than one occurrence is Q halide.
In a more highly preferred embodiment, Q is a fluorinated C1-20 hydrocarbyl group, most preferably, a fluorinated aryl group, especially, pentafluorophenyl.
Illustraη ve, but not limiη ng, examples of ion forming compounds comprising proton donatable caη ons which may be used as acη vaη ng cocatalysts in the preparaη on of the catalysts of this invenη on are tri-subsη tuted ammonium salts such as: trimethylammonium tetraphenylborate, methyldioctadecylamrnoniurn tetraphenylborate, triethylammonium tetraphenylborate, tripropylammonium tetraphenylborate, tri(n-butyl)ammonium tetraphenylborate, methyltetradecyloctadecylammonium tetraphenylborate, N,N-dimethylanilinium tetraphenylborate, N,N-diethylanilinium tetraphenylborate, N,N-dimethyl(2.4,6-trimethylanilinium) tetraphenylborate, trimemylammomumtetrakis(penta-fluorophenyl)borate, triethylammonium tetrakis(pentafluorophenyl)borate, tripropylammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammoniumtetrakis(pentafluorophenyl)borate, tri(sec-butyl)ammoniumtetrakis(pentafluorophenyl)borate, N,N-dimethylaniliniumtetrakis(pentafluorophenyl)borate, N22iiethylaniliniumtetrakis(pentafluorophenyl)borate, N,N-dimethyl(2,4,6-rrimethylanilinium)tetrakis(pentafluorophenyl)borate, trimethylammonium tetrakis(2,3,4,6-tetrafluorophenyl)borate,

triethylammonium tetrakis(2,3,4,6-tetrafluorophenyl)borate, tripropy lammonium tetrakis(2,3,4,6-tetrafluorophenyl)borate, tri(n-butyl)ammoniumtetrakis(2,3,4,6-tetrafluorophenyl)borate, dimethyl(t-butyl)ammoniumtetrakis(2,3,4,6-tetrafluorophenyl)borate, N,N-dimethylaniliniumtetrakis(2,3,4,6-tetrafluorophenyl)borate, N,N-diethylanilinium tetrakis(2,3,4,6-tetrafluorophenyl)borate, and N,N-dimethyl-(2,4,6-trimethylanilinium) tetrakis-(2,3,4,6-tetrafluoro-phenyl)borate.
Dialkyl ammonium salts such as: di-(i-propyl)ammonium tetrakis(pentafluorophenyl)borate, and dicyclohexylammonium tetrakis(pentafluorophenyl)borate.
Tri-subsη tuted phosphonium salts such as: triphenylphosphoniumtetrakis(pentafluorophenyl)borate, tri(o-tolyl)phosphonium tetrakis(pentafluorophenyl)borate, and tri(2,6-dimethylphenyl)phosphoniumtetrakis(pentafluorophenyl)borate.
Preferred are tetrakis(pentafiuorophenyl)borate salts of long chain alkyl mono-and disubsη tuted ammonium complexes, especially C14-C20 alkyl ammonium complexes, especially methyldi(octadecyl)ammonium tetrakis(pentafluorophenyl)borate and methyldi(tetradecyl)ammonium tetrakis(pentafluorophenyl)borate.

An especially preferred group of acη vaη ng2 cocatalysts is
tris(pentafluorophenyl)borane, N-R3,N-R4 anilinium tetrakis(pentafluorophenyl)borate
where R3 and R4 independently each occurrence are subsη tuted or unsubsη tuted
saturated hydrocarbyl groups having from 1 to 8 carbon atoms, (RiR2NHCH3)+
(C6H4OH)B(C6F5)3\ or (R,R2NHCH3)+ B(C6F5y, where Ri and R2 independently each
occurrence are subsη tuted or unsubsη tuted saturated hydrocarbyl groups having from
12 to 30 carbon atoms. Another suitable ion forming, acη vaη ng cocatalyst comprises a salt of a caη onic oxidizing agent and a noncoordinaη ng, compaη ble anion represented by the formula:

wherein:
Oxe+ is a caη onic oxidizing agent having charge e+; e is an integer from 1 to 3; and Ad", and d are as previously defined.
Examples of caη onic oxidizing agents include: ferrocenium, hydrocarbyl-subsη tuted ferrocenium, Ag+, or Pb+2. Preferred embodiments of A2_ are those anions previously defined with respect to the Bronsted acid containing acη vaη ng cocatalysts, especially tetrakis(pentafluorophenyl)borate.
Another suitable ion forming, acη vaη ng cocatalyst comprises a compound which is a salt of a carbenium ion or silylium ion and a noncoordinaη ng, compaη ble anion represented by the formula:

wherein:
©+ is a Ci_20 carbenium ion or silylium ion; and
A- is as previously defined.
A preferred carbenium ion is the trityl caη on, that is triphenylcarbenium. A preferred silylium ion is triphenylsilylium.
Ionic compounds (a) suitable for use in the present invenη on and their methods of preparaη on are described in U.S. patent applicaη on No. 08/610,647, filed March 4, 1996 (corresponding to WO-96/28480) which is incorporated herein by reference. The term used in the anion a.2) of the ionic compound "at least one subsη tuent comprising an acη ve hydrogen moiety" means in the present applicaη on a subsη tuent comprising a hydrogen atom bonded to an oxygen, sulphur, nitrogen or phosphorous atom.
In the anion a.2), the at least one subsη tuent comprising an acη ve hydrogen moiety preferably corresponds to the formula

wherein G is a polyvalent hydrocarbon radical, the group (T-H) is a radical wherein T comprises O, S. NR, or PR, the O, S, N, or P atom of which is bonded to hydrogen

atom H, wherein R is a hydrocarbyl radical, a trihydrocarbyl silyl radical, a trihydrocarbyl germyl radical, or hydrogen, H is hydrogen, q is 0 or 1, and preferably 1, and r is an integer from 1 to 3, preferably 1. Polyvalent hydrocarbon radical G has r+1 /alencies, one valency being associated with a metal or metalloid of the Groups 5-15 of ;he Periodic Table of the Elements in the anion, the other r valencies of G being ittached to r groups (T-H). Preferred examples of G include di- or trivalent hydrocarbon radicals such as: alkylene, arylene, aralkylene, or alkarylene radicals containing from 1 to 20 carbon atoms, more preferably from 2 to 12 carbon atoms. Suitable examples of divalent hydrocarbon radicals G include phenylene, biphenylene, naphthylene, methylene, ethylene, 1,3-propylene, 1,4-butylene, phenylmethylene (-C6H4-CH2-). The polyvalent hydrocarbyl porη on G may be further subsη tuted with radicals that do not negaη vely impact the effect to be achieved by the present invenη on. Preferred examples of such noninterfering subsη tuents are alkyl, aryl, alkyl- or aryl-subsη tuted silyl and germyl radicals, and fluoro subsη tuents.
The group (T-H) in the previous formula may be an -OH, -SH, -NRH, or -PRH group, wherein R preferably is a Cj_i8, preferably a C\.\2, hydrocarbyl radical or hydrogen, and H is hydrogen. Preferred R groups are alky Is, cycloalkyls, aryls, arylalkyls, or alkylaryls of 1 to 18 carbon atoms, more preferably those of 1 to 12 carbon atoms. Alternaη vely, the group (T-H) comprises an -OH, -SH, -NRH, or -PRH group which are part of a larger funcη onal moiety such as, for example, C(OK>H, C(S)-OH, C(S)-SH, C(0)-SH, C(0)-NRH, C(S)-NRH, and C(O)-PRH, and C(S)-PRH. Most preferably, the group (T-H) is a hydroxy group, -OH, or an amino group. -NRH.
Very preferred subsη tuents Gq(T-H) in anion a.2) include hydroxy- and amino-subsη tuted aryl, aralkyl, alkaryl or alkyl groups, and most preferred are the hydroxyphenyls. especially the 3- and 4-hydroxyphenyl groups and 2,4-dihydroxyphenyl, hydroxytolyls, hydroxybenzyls (hydroxymethylphenyl), hydroxybiphenyls, hydroxynaphthyls, hydroxycyclohexyls, hydroxymethyls, and hydroxypropyls. and the corresponding amino-subsη tuted groups, especially those subsη tuted with -NRH wherein R is an alkyl or aryl radical having from 1 to 10 carbon atoms, such as for example methyl, ethyl, propyl, i-propyl, n-, i-, or t-butyl, pentyl,

hexyl, heptyl, octyl, nonyl, and decyl, phenyl, benzyl, tolyl, xylyl, naphthyl, and biphenyl.
The anion a.2) may further comprise a single Group 5-15 element or a plurality of Group 5-15 elements but is preferably a single coordinaη on complex comprising a charge-bearing metal or metalloid core. Preferred anions a.2) are those containing a single coordinaη on complex comprising a charge-bearing metal or metalloid core carrying the at least one subsη ruent containing an acη ve hydrogen moiety. Suitable metals for the anions of ionic compounds (a) include, but are not limited to, aluminum, gold, plaη num and the like. Suitable metalloids include, but are not limited to elements of groups 13, 14, and 15, of the Periodic Table of the Elements, preferably are, boron, phosphorus, and silicon. Ionic compounds which contain anions comprising a coordinaη on complex containing a single boron atom and one or more subsη tuents comprising an acη ve hydrogen moiety are preferred. Examples of suitable anions comprising a single Group 5-15 element are disclosed in EP 0 277 004 and examples of those having a plurality of Group 5-15 elements are disclosed in EP 0 277 003, with the proviso that at least one of the subsituents in the anions described therein is subsη tuted by a subsη ruent comprising an acη ve hydrogen moiety, preferably Gq(T-H)r.
Preferably, anions a.2) may be represented by a single coordinaη on complex of the following general Formula (II):

wherein:
M" is a metal or metalloid selected from Groups 5-15 of the Periodic Table of the Elements;
Q independently in each occurrence is selected from the group consisη ng of hydride, dihydrocarbylamido, preferably dialkylamido, halide, hydrocarbyloxide, preferably alkoxide and aryloxide, hydrocarbyl, and subsη tuted-hydrocarbyl radicals, including halo-subsη tuted hydrocarbyl radicals, and hydrocarbyl- and halohydrocarbyl-subsη tuted organo-metalloid radicals, the hydrocarbyl porη on in each of these groups preferably having from 1 to 20 carbons, with the proviso that in not more than one occurrence is Q halide;
G is a polyvalent hydrocarbon radical having r+1 valencies, and preferably a

divalent hydrocarbon radical, bonded to M" and r groups (T-H);
the group (T-H) is a radical wherein T comprises O, S, NR, or PR, the O, S, N, or P atom of which is bonded to hydrogen atom H, wherein R is a hydrocarbon radical, a trihydrocarbyl silyl radical, a trihydrocarbyl germyl radical, or hydrogen;
m is an integer from 1 to 7, preferably 3;
n is an integer from 0 to 7, preferably 3;
q is an integer 0 or 1, preferably 1;
r is an integer from 1 to 3, preferably 1;
z is an integer from 1 to 8, preferably 1 or 2;
d is an integer from 1 to 7, preferably 1; and
n+z-m = d.
When q is 0 and polyvalent hydrocarbon radical G is not present, T is bound to M". Preferred boron-containing anions a.2) which are parη cularly useful in this invenη on may be represented by the following general Formula (III):

wherein:
B is boron in a valence state of 3;
z" is an integer from 1-4, preferably 1 or 2, most preferably 1;
d is 1; and
Q, G, T. H, q, and r are as defined for Formula (II). Preferably, z" is 1 or 2, q is 1, and r is 1.
Illustraη ve, but not limiη ng, examples of anions a.2) of ionic compounds to be used in the present invenη on are boron-containing anions such as: triphenyl(hydroxyphenyl)borate, triphenyl(2,4-dihydroxyphenyl)borate, tri(p-tolyl)(hydroxyphenyl)borate,
tris-(pentafluoropheny l)(hydroxypheny l)borate, tris-(2,4-dimethylphenylXhydroxyphenyl)borate, tris-(3,5 -dimethy lphenyl)(hydroxyphenyl)borate,
tris-(3,5-di-trifluoromethyl-phenyl)(hydroxyphenyl)borate,tris(pentafluorophenyl)(2-hydroxyethyl)borate, tris(pentafluorophenyl)(4-hydroxybutyl)borate, tris(pentafluorophenyl)(4-hydroxycyclohexyl)borate, tris(pentafluorophenyl)(4-(4"-

hydroxyphenyl)phenyl)borate, tris(pentafluorophenyl)(6-hydroxy-2-naphthyl)borate, and the like.
Further preferred anions a.2) include those containing two subsη tuents containing an acη ve hydrogen moiety, for example: diphenyldi(hydroxyphenyl)borate, diphenyldi(2,4-dihydroxyphenyl)borate,di(p-tolyl)di(hydroxyphenyl)borate, di(pentafluorophenyl)di-(hydroxyphenyl)borate, di(2,4-dimethylphenyl) di(hydroxyphenyI)borate, di (3,5-dimethylphenyl) di(hydroxyphenyl)borate, di (3,5-di-trifluoromethylphenyl) di(hydroxyphenyl)borate, di(pentafluorophenyl) di(2-hydroxyethyl)borate, di(pentafluorophenyl) di(4-hydroxybutyl)borate, di(pentafluorophenyl) di(4-hydroxycyclohexyl)borate, di(pentafluorophenyl) di(4-(4"-hydroxyphenyl )phenyl)borate, di(pentafluorophenyl) di(6-hydroxy-2-naphthyl)borate, and the like.
Other preferred anions are those above menη oned borates wherein the hydroxy funcη onality is replaced by an amino NHR funcη onality wherein R preferably is methyl, ethyl, or t-butyl. A highly preferred anion a.2) is tris(pentafluorophenyl)(4-hydroxyphenyl) borate.
The canonic porη on a. 1) of the ionic compound is preferably selected from the group consisη ng of Bronsted acidic caη ons, especially ammonium and phosphonium caη ons or sulfonium caη ons, carbonium caη ons, silylium caη ons, oxonium caη ons, and caη onic oxidizing agents. The caη ons a. 1) and the anions a.2) are used in such raη os as to give a neutral ionic compound.
Bronsted acidic caη ons may be represented by the following general formula:
(L-H)+
wherein:
L is a neutral Lewis base, preferably a nitrogen, phosphorus, oxygen, or sulfur containing Lewis base; and (L-H)+ is a Bronsted acid.
Illustraη ve, but not limiη ng, examples of Bronsted acidic caη ons are trihydrocarbyl- and preferably trialkyl-subsη tuted ammonium caη ons such as triethylammonium, tripropylammonium, tri(n-butyl)ammonium, trimethylammonium, tri(i-butyl)ammonium, and tri(n-octyl)ammonium. Also suitable are N,N-dialkyl anilinium caη ons such as N,N-dimethylanilinium, N,N-diethyl-anilinium, N,N-2,4,6-

pentamethylanilinium, N,N-dimethylbenzylammonium and the like; dialkylammonium caη ons such as di-(i-propyl)ammonium, dicyclohexylammonium and the like; and triarylphosphonium caη ons such as triphenylphosphonium, tri(methyl-phenyl)phosphonium, tri(dimethylphenyl)phosphonium, dimethylsulphonium, diethylsulphonium, and diphenylsulphonium.
In a highly preferred embodiment, the Bronsted acidic caη on a.l) may be represented by the following general formula:
[L*-H]+, wherein:
L is a nitrogen, oxygen, sulfur or phosphorus containing Lewis base which comprises at least one relaη vely long chain alkyl group. Preferably such L* groups contain from one to three C i Q-40 alkyl groups with a total of from 12 to 100 carbons, more preferably two C \ 0.40 alkyl groups and from 21 to 90 total carbons. It is understood that the caη on may comprise a mixture of alkyl groups of differing lengths. For example, one suitable caη on is the protonated ammonium salt derived from the commercially available long chain amine comprising a mixture of two C14, Cjg or Cjg alkyl groups and one methyl group. Such amines are available from Witco Corp., under the trade name Kemamine™ T9701, and from Akzo-Nobel under the trade name Armeen™ M2HT. These preferred caη ons are described in U.S. provisional applicaη on No. 60/QI42&42filed March 27, 1996, which is incorporated herein by reference. Ionic compounds (a) comprising the caη on [L*-H]+ can be easily prepared by subjecη ng an ionic compound comprising the caη on [L-H]+ and the anion a.2), as prepared in U.S. patent applicaη on No. 08/610,647, filed March 4, 1996 (corresponding to WQ-26/28480), to a caη on exchange reacη on with a [L*-H]+ salt.
Illustraη ve, but not limiη ng examples of the highly preferred caη ons a.l) of the ionic compound (a) are tri-subsη tuted ammonium salts such as: decyldi(methyl)ammonium, dodecyldi(methyl)ammonium, tetradecyldi(memyl)ammonium, hexaadecyldi(methyl)ammonium, octadecyldi(methyl)ammonium, eicosyldi(methyl)ammonium, methyldi(decyl)ammonium, methyldi(dodecyl)ammonium, methyldi(tetradecyl)ammonium, methyldi(hexadecyl)ammonium,

methyldi(octadecyl)ammonium, methyldi(eicosyl)ammonium, tridecylammonium, tridodecylammonium, tritetradecylammonium, trihexadecylammonium, trioctadecylammonium, trieicosylammonium, decyldi(n-butyl)ammonium, dodecyldi(n-butyl)ammoniiim, octadecyldi(n-butyl)ammonium, N,N-didodecylanilinium, N-methyl-N-dodecylanilinium,
N,N-di(octadecyl)(2,4,6-trimethylanilinium), cyclohexyldi(dodecyl)ammonium, and methyldi (dodecyl)ammonium.
Suitable similarly subsη tuted sulfonium or phosphonium caη ons such as, di(decyl)sulfonium, (n-butyl)dodecylsulfonium, tridecylphosphonium, di(octadecyl)methylphosphonium, and tri(tetradecyl)phosphonium, may also be named.
Preferred ionic compounds (b) are di(octadecyl)methylammonium tris(pentafluorophenyl)(hydroxyphenyl)borate, octadecyl dimethylammonium tris(pentafluorophenyl)(hydroxyphenyl)borate and di(octadecyl) (n-butyl)ammonium tris(pentafluorophenyl)(hydroxyphenyl)borate, as well as the amino (-NHR) analogues of these compounds wherein the hydroxyphenyl group is replaced by the aminophenyl group.
A second type of suitable caη on corresponds to the formula: ©+, wherein ©+ is a stable carbonium or silylium ion containing up to 30 nonhydrogen atoms. Suitable examples of caη ons include tropyllium, triphenylrnethylium, benzene(diazonium). Silylium salts have been previously geneη cally disclosed in J. Chem. Soc. Chem. Comm., 1993, 383-384, as well as Lambert, J.B., et. al., Organometallics, 1994, 13, 2430-2443. Preferred silylium caη ons are triethylsilylium, and trimethylsilylium and ether subsη tuted adducts thereof.
Another suitable type of caη on comprises a caη onic oxidizing agent represented by the formula:
0Xe+ wherein Oxe+ is a caη onic oxidizing agent having a charge of e+, and e is an integer from 1 to 3.
Examples of caη onic oxidizing agents include: ferrocenium, hydrocarbyl-subsη tuted ferrocenium, Ag+, and Pb2+

In general, the catalyst system can be prepared by combining the catalyst components in any order in a suitable solvent at a temperature within the range from about "100°C to about 300°C or by generaη ng the acη vated catalyst electrochemically as previously explained, followed by wet or dry deposiη on and impregnaη on of the support material component. Alternaη vely, the metallocene complex component and the acη vator component may be individually deposited on the support material component in any order, opη onally with individual solvent removal and/or drying. The acη vated catalyst may be separately prepared prior to use by combining the respecη ve components. The catalyst and cocatalyst as well as acη vated catalyst system generally are sensiη ve to both moisture and oxygen and should be handled and transferred in an inert atmosphere.
The catalyst system of this invenη on is produced from catalyst components comprising a support material component. Especially suited support materials for the support material component of the catalyst system include polymers, inorganic oxides, metal halides, prepolymerized polymeric substrates or a mixture thereof,) A preferred group of support materials is inorganic oxides and includes silica, alumina, silica-alumina, or a mixture thereof. Other suitable support materials include silica, alumina, silica-alumina, or a mixture thereof which has been modified with η C2, B2O3, or a mixture thereof!, Suitable supported catalyst systems are readily prepared by contacη ng the present metal complexes with the substrate, opη onally while subjecη ng the mixture to heaη ng and/or reduced pressures.
Preferred supports for use in the present invenη on include highly porous silicas,
aluminas, aluminosilicates, and mixtures thereof. The most preferred support material
is silica. The support material may be in granular, agglomerated, pelleη zed, or any
other physical form. Suitable materials include, but are not limited to, silicas available
from Grace Davison (division of W.R. Grace & Co.) under the designaη ons SD
3216.30, Davison Syloid™ 245, Davison 948 and Davison 952, and from Degussa AG
under the designaη on Aerosil™ 812; and aluminas available from Akzo Chemicals Inc.
under the designaη on Ketzen™ Grade B.
" Supports suitable for the present invenη on preferably have a surface area as
determined by nitrogen porosimetry using the B.E.T. method from 10 to about 1000

m2/g, and preferably from about 100 to 600 nrVg. The pore volume of the support, as determined by nitrogen adsorpη on, advantageously is between 0.1 and 3 cm2/g, preferably from about 0.2 to 2 cm2/g. The average parη cle size is not criη cal, but typically is from 3.5 to 500 urn, preferably from 1 to 100 urn.
Both silica and alumina are known to inherently possess small quanη η es of hydroxyl funcη onality attached thereto. When used as a support herein, these materials are preferably subjected to a heat treatment and/or chemical treatment to reduce the hydroxyl content thereof. Typical heat treatments are carried out at a temperature from 30°C to 1000°C for a duraη on of 10 minutes to 50 hours in air or an inert atmosphere or under reduced pressure. Typical chemical treatments include contacη ng with Lewis acid alkylaη ng agents such as trihydrocarbyl aluminum compounds, trihydrocarbylchlorosilane compounds, trihydrocarbylalkoxysilane compounds or similar agents. Preferred silica or alumina materials for use herein have a surface hydroxyl content that is less than 0.8 mmol of hydroxyl groups per gram of solid support, more preferably less than 0.5 mmol per gram. The hydroxyl content may be determined by adding an excess of dialkyl magnesium to a slurry of the solid support and determining the amount of dialkyl magnesium remaining in soluη on via known techniques. This method is based on the reacη on:
S-OH + Mg(Alk)2 --> S-OMg(Alk) + (Alk)H, wherein S is the solid support, and Alk is a C 1.4 alkyl group.
The support may be unfuncη onalized (excepη ng for hydroxyl groups as previously discussed) or funcη onalized by treaη ng with a silane or chlorosilane funcη onalizing agent to attach thereto pendant silane -(Si-R)=, or chlorosilane -(Si-Cl)= funcη onality, wherein R is a C\.\Q hydrocarbyl group. Suitable funcη onalizing agents are compounds that react with surface hydroxyl groups of the support or react with the silicon or aluminum of the matrix. Examples of suitable funcη onalizing agents include phenylsilane, diphenylsilane, methylphenylsilane, dimethylsilane, diethylsilane, cUorofrimethylsilane, hexamethyldisilazane, dichlorosilane, and dichlorodimethylsilane. Techniques for forming such funcη onalized silica or alumina compounds were previously disclosedin U.S. Patent No."s 3,687,920 and 3,879,368, the teachings of which are herein incorporated by reference.

The support may also be treated with an aluminum component selected from an alumoxane or an aluminum compound of the formula AIR3, wherein R independently each occurrence is hydride or R1, and R1 is Cj_4 alkyl. Preferably, the aluminum component is selected from the group consisη ng of aluminoxanes and tris(Cj.4 alkyl)aluminum compounds. Most preferred aluminum components are aluminoxanes, trimethylaluminum, triethylaluminum, tri-isobutylaluminum, and mixtures thereof.
Alumoxanes (also referred to as aluminoxanes) are oligomeric or polymeric aluminum oxy compounds containing chains of alternaη ng aluminum and oxygen atoms, whereby the aluminum carries a subsη tuent, preferably an alkyl group. The structure of alumoxane has been believed to be represented by the following general formulae (-A1CR1 )-0)m", for a cyclic alumoxane, and R2Al-CK-AKR2-OJm"-AlR2, for a linear compound, wherein Rl is Cj_4 alkyl, and m" is an integer ranging from 1 to about 50, preferably at least about 4. Alumoxanes are typically the reacη on products of water and an alkylaluminum compound, which in addiη on to an alkyl group may contain halide or alkoxide groups. Reacη ng a mixture of several different alkylaluminum compounds, such as for example trimethylaluminum and tri-isobutylaluminum, with water yields so-called modified or mixed alumoxanes. Preferred alumoxanes are methylalumoxane and methylalumoxane modified with minor amounts of C2-4 alkyl groups, especially isobutyl groups. Alumoxanes generally contain minor to substanη al amounts of starη ng alkylaluminum compound.
Parη cular techniques for the preparaη on of alumoxane type compounds by contacη ng an alkylaluminum compound with an inorganic salt containing water of crystallizaη on are disclosed in US-A-4,542,119. In a parη cular preferred embodiment, an alkylaluminum compound is contacted with a regeneratable water-containing substance such as hydrated alumina, silica or other substance. This is disclosed in EP-A-338,044. Thus the alumoxane may be incorporated into the support by reacη on orThyalufelfaluminaor silica material, which has opη onally been funcη onalized with silane, siloxane. hydrocarbyloxysilane, or chlorosilane groups, with a tris(Ci_io alkyl) aluminum compound according to known techniques. For the teachings contained therein the foregoing patents and publicaη ons, or their corresponding equivalent United States applicaη ons, are hereby incorporated by reference.

The treatment of the support material in order to include opη onal alumoxane or trialkylaluminum loadings involves contacη ng the same with an alumoxane or trialkylaluminum compound before, after, or simultaneously with addiη on of the complex or acη vated catalyst. Opη onally the mixture can also be heated under an inert atmosphere for a period and at a temperature sufficient to fix the alumoxane, trialkylaluminum compound, complex or catalyst system to the support. Opη onally, the treated support component containing alumoxane or the trialkylaluminum compound may be subjected to one or more wash steps, using toluene or similar solvent, to remove excess alumoxane, trialkylaluminum, or any other soluble aluminum compound that is not fixed to the support.
Besides contacη ng the support with alumoxane, the alumoxane may be generated in situ by contacη ng an unhydrolyzed silica or alumina or a moistened silica or alumina with a trialkyl aluminum compound opη onally in the presence of an inert diluent. Such a process is well known in the art, having been disclosed in EP-A-250,600, U.S.-A-4,912,075, and U.S.-A-5,008,228, the teachings of which, or of the corresponding U. S. applicaη on, are hereby incorporated by reference. Suitable aliphaη c hydrocarbon diluents include pentane, isopentane, hexane, heptane, octane, isooctane, nonane, isononane, decane, cyclohexane, methylcyclohexane and combinaη ons of two or more of such diluents. Suitable aromaη c hydrocarbon diluents are benzene, toluene, xylene, and other alkyl or halogen subsη tuted aromaη c compounds. Most preferably, the diluent is an aromaη c hydrocarbon, especially toluene. After preparaη on in the foregoing manner the residual hydroxyl content thereof is desirably reduced to a level less than 1.0 meq of OH per gram of support, by any of the previously disclosed techniques.
The cocatalysts of the invenη on may also be used in combinaη on with a tri(hydrocarbyl)aluminum compound having from 1 to 10 carbons in each hydrocarbyl group, an oligomeric or polymeric alumoxane compound, a
di(hydrocarbylXhydrocarbyloxy)aluminum compound having from 1 to 10 carbons in each hydrocarbyl or hydrocarbyloxy group, or a mixture of the foregoing compounds, if desired. These aluminum compounds are usefully employed for their beneficial ability to scavenge impuriη es such as oxygen, water, and aldehydes from the polymerizaη on

mixture. Preferred aluminum compounds include C2-6 trialkyl aluminum compounds, especially those wherein the alkyl groups are ethyl, propyl, isopropyl, n-butyl, isobutyl, pentyl, neopentyl, or isopentyl, and methylalumoxane, modified methylalumoxane and diisobutylalumoxane. The molar raη o of aluminum compound to metal complex is preferably from 10,000:1 to 1:1000, more preferably from 5000:1 to 1:100, most preferably from 1:100 to 100:1.
In one embodiment of this invenη on the catalyst system is produced so that it contains alumoxane in a nonacη vaη ng amount. Alternaη vely, the catalyst system may be produced so that it is essenη ally alumoxane-free.
The molar raη o of catalyst/cocatalyst employed ranges from 1:1000 to 10:1, preferably ranges from 1:10 to 10:1, more preferably from 1:5 to 1:1, most preferably from 1:1.2 to 1:1. Mixtures of the acη vaη ng cocatalysts of the present invenη on may also be employed if desired.
In a highly preferred embodiment of this invenη on, the catalyst system of this invenη on is prepared so that the acη vator component, preferably comprising a cocatalyst, is used in a range of molar raη os to the metallocene complex component of from about 0.3 to about 5, preferably from about 0.5 to about 2.5, more preferably from about 1 to about 2, and even more preferably from about 1 to about 1.5.
An important factor in realizing high efficiencies with the catalyst system of this invenη on is the range of catalyst loadings, that is, the amount of the metallocene complex component based on the molar amount of the central metal of the complex relaη ve to the weight of the support material component. Desirably, the metallocene complex component is used in a loading range of from about 0.1 to about 25 nmol/gram of support material component, preferably, from about 0.3 to about 20 Hmol/gram of support material component, more preferably, from about 1 to about 20 Hmol/gram of support material component.
In most polymerizaη on reacη ons the molar raη o of catalyst to polymerizable compounds employed is from 10"*2; 1 to 10"1: 1, more preferably from 10" 2; l to 10"5:1.
Molecular weight control agents can be used in combinaη on with the present cocatalysts. Examples of such molecular weight control agents include hydrogen,

trialkyl aluminum compounds or other known chain transfer agents. Hydrogen may be present in the polymerizaη on reactor used for the polymerizaη on process of this invenη on, desirably in a hydrogen to monomer molar raη o which is less than 0.05, more desirably less than 0.02, and preferably less than 0.01.
The supported catalysts in any of the processes of this invenη on, whether gas phase, slurry, or any other polymerizaη on process, may be used to polymerize addiη onal polymerizable monomers including ethylenically unsaturated monomers, acetylenic compounds, conjugated or nonconjugated dienes, polyenes, and mixtures thereof. Preferred monomers include olefins, for example, a-olefins having from 2 to 100,000, preferably from 2 to 30, more preferably from 2 to 8 carbon atoms and combinaη ons of two or more of such a-olefins.
Parη cularly suitable a-olefins include, for example, ethylene, propylene, 1-butene, 1-pentene, 4-methylpentene-l, 1-hexene, 1-heptene, 1-octene, 1-nonene, l-decene,)l-undecene, 1-dodecene, 1-tridecene, 1 -tetradecene, 1-pentadecene, and Cj6 - C30 a-olefins or combinaη ons thereof, as well as long chain vinyl terminated oligomeric or polymeric reacη on products formed during the polymerizaη on. Preferably, the a-olefins are ethylene, propene, 1-butene, 4-methyl-pentene-1, 1-hexene, 1-octene, and combinaη ons of ethylene and/or propene with one or more of such other a-olefins. Other preferred monomers include styrene, halo- or alkyl subsη tuted styrenes, tetrafiuoroethylene, vinylcyclobutene, vinylcyclohexene, vinylcyclohexane. vinyl chloride, 1,4-hexadiene, dicyclopentadiene, ethylidene norbornene, and 1,7-octadiene. Mixtures of the above-menη oned monomers may also be employed.
/ A preferred group of olefin comonomers for polymerizaη ons where ethylene is the monomer includes propene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1,7-octadiene, 1,5-hexadiene, 1,4-pentadiene, 1,9-decadiene, ethylidenenorbornene, styrene, or a mixture thereof For polymerizaη ons wherein propene is the monomer, the preferred comonomers are the same as that immediately previous, but with the inclusion of ethylene instead of propene.

Long chain macromolecular a-olefins can be vinyl terminated polymeric remnants formed in situ during conη nuous soluη on polymerizaη on reacη ons, and in some other polymerizaη on reacη ons, such as gas phase polymerizaη on reacη ons. Under suitable process condiη ons such long chain macromolecular units may be polymerized into the polymer product along with ethylene and other short chain olefin monomers to give small quanη η es of long chain branching in the resulη ng polymer.
In general, the polymerizaη on may be accomplished under condiη ons well known in the prior art for Ziegler-Natta or Kaminsky-Sinn type polymerizaη on reacη ons. Suspension, soluη on, slurry, gas phase or high pressure, whether employed in batch or conη nuous form or other process condiη ons, may be employed if desired. Examples of such well known polymerizaη on processes are depicted in WO 88/02009, U.S. Patent Nos. 5,084,534; 5,405,922; 4,588,790; 5,032,652; 4,543,399; 4,564,647; 4,522,987, which are incorporated herein by reference; and elsewhere. Preferred polymerizaη on temperatures are from 0-250°C. Preferred polymerizaη on pressures are from atmospheric to 3000 atmospheres.
In a highly desirable embodiment, the processes of this invenη on are performed in a single reactor, which may have a single reacη on vessel or two or more vessels producing essenη ally the same polyolefin copolymer composiη on. Thus, in this embodiment, the polymerizaη on processes of this invenη on do not produce blends, or where more than one reacη on vessel is used do not require blending to produce essenη ally homogeneous polyolefin copolymer composiη ons. Alternaη vely, the catalyst system may employ more than one metallocene complex, or even a nonmetallocene component, to produce reactor blends.
In an important aspect of this invenη on, which contributes to the high catalyst efficiencies obtainable with the catalyst system of this invenη on, it is desirable that the catalyst system is used at a catalyst concentraη on in the range of about 0.01 x 10"" to about 6 x 10"6 moles acη ve catalyst/mole monomer, more desirably, at a catalyst concentraη on in the range of about 0.01 x 10"6 to about 5.0 x 10"6 moles acη ve catalyst/mole monomer, preferably, at a catalyst concentraη on in the range of about 0.02 x 10"6 to about 3.0 x 10-6 moles acη ve catalyst/mole monomer, more preferably, at a catalyst concentraη on in the range of about 0.05 x 10-6 to about 3.0 x 10-6 moles

acη ve catalyst/mole monomer, and sη ll more preferably, at a catalyst concentraη on in the range of about 0.1 x 10"6 to about 3.0 x 10-6 moles acη ve catalyst/mole monomer. Acη ve catalyst is defined in this context as the central metal of the metallocene complex of the metallocene complex component of the catalyst system.
Use of the catalyst system of this invenη on in the polymerizaη on process thereof results in a catalyst efficiency that is at least 24,000,000 g polymer/mole catalyst/hour, desirably, at least 48,000,000 g polymer/mole catalyst/hour, more desirably, at least 72,000,000 g polymer/mole catalyst/hour, even better, at least 96,000,000 g polymer/mole catalyst/hour, sη ll better, at least 144,000,000 g polymer/mole catalyst/hour, even better than that, at least 240,000,000 g polymer/mole catalyst/hour, better sη ll, at least 384,000,000 g polymer/mole catalyst/hour. As used in relaη onship to the term "catalyst efficiency", the mass of polymer, in grams, refers to the mass of polymer produced in the polymerizaη on process relaη ve to the mass, in moles, of the acη ve catalyst required per hour. If the catalyst system is employed in one of the alternaη ve methods described herein, the mass of the catalyst system is simply the sum of the masses of the catalyst components.
The polymerizaη on process of this invenη on may be conducted under those generally useful for slurry polymerizaη on processes. A descripη on of the slurry process can be found in Volume 6 of the Encyclopedia of Polymer Science and Engineering (John Wiley and Sons) pages 472 to 477 (1986).
By conducη ng the slurry polymerizaη on under appropriately controlled reacη on condiη ons, the polymer being formed around the solid catalyst system is not melted or dissolved during the polymerizaη on reacη on, but maintains a discrete form, which, preferably, is a granular or powdery form during the reacη on.
When a polymerizaη on reacη on is conducted under slurry process condiη ons, the polymerizaη on pressure is generally from 1 to 100 atm, preferably from 3 to 30 atm, and the polymerizaη on temperature is generally from 20 to 115 °C, preferably from 50 to 105 °C. However, the upper limit of the polymerizaη on temperature is a temperature above which the polymer produced does not maintain its discrete state, and this varies depending on the type and density of the polymer produced and the type of diluent used.

As a diluent to be used for slurry polymerizaη on, typical inert aliphaη c or aromaη c hydrocarbon solvents can be suitably used, including xylene, benzene, toluene, isobutane, isopentane, heptane, hexane and octane. Hexane, isobutane and isopentane are especially preferred.
In producing a polymer by the process of this invenη on under slurry condiη ons, the molecular weight can be controlled by changing the concentraη on of hydrogen in the reacη on system or by changing the polymerizaη on temperature, as described in EP 69951, DE 3127133.2, and U.S. 4,542,199 which are hereby incorporated herein by reference.
The process of the present invenη on can be employed to advantage jn thejas phase polymerizaη on and copolymerizaη on of olefins. Gas phase processes for the polymerizaη on of olefins, especially the homopolymerizaη on and copolymerizaη on of ethylene and propylene, and the copolymerizaη on of ethylene with higher a-olefins such as, for example, 1-butene, 1-hexene, 4-methyl-l-pentene, are well known in the art.
The gas phase process employed can be, for example, of the type which employs a mechanically sη rred bed or a gas fluidized bed as the polymerizaη on reacη on zone. Preferred is the process wherein the polymerizaη on reacη on is carried out in a verη cal cylindrical polymerizaη on reactor containing a fluidized bed of polymer parη cles supported above a perforated plate, fluidizaη on grid, by a flow of fluidizaη on gas.
The gas employed to fluidize the bed comprises the monomer or monomers to be polymerized, and also serves as a heat exchange medium to remove the heat of reacη on from the bed. The hot gases emerge from the top of the reactor, normally via a tranquilizaη on zone, also known as a velocity reducη on zone, having a wider diameter than the fluidized bed and wherein fine parη cles entrained in the gas stream have an opportunity to gravitate back into the bed. It can also be advantageous to use a cyclone to remove ultra-fine parη cles from the hot gas stream. The gas is then normally recycled to the bed by means of a blower or compressor and one or more heat exchangers to strip the gas of the heat of polymerizaη on.

A preferred method of cooling the bed, in addiη on to the cooling provided by the cooled recycle gas, is to feed a volaη le liquid to the bed to provide an evaporaη ve cooling effect. The volaη le liquid employed in this case can be, for example, a volaη le inert liquid, for example, a saturated hydrocarbon having about 3 to about 8, preferably 4 to 6, carbon atoms. In the case that the monomer or comonomer itself is a volaη le liquid, or can be condensed to provide such a liquid, this can suitably be fed to the bed to provide an evaporaη ve cooling effect. Examples of olefin monomers which can be employed in this manner are olefins containing about three to about eight, preferably three to six carbon atoms. The volaη le liquid evaporates in the hot fluidized bed to form gas which mixes with the fluidizing gas. If the volaη le liquid is a monomer or comonomer, it will undergo some polymerizaη on in the bed. The evaporated liquid then emerges from the reactor as part of the hot recycle gas, and enters the compression/heat exchange part of the recycle loop. The recycle gas is cooled in the heat exchanger and, if the temperature to which the gas is cooled is below the dew point, liquid will precipitate from the gas. This liquid is desirably recycled conη nuously to the fluidized bed. It is possible to recycle the precipitated liquid to the bed as liquid droplets carried in the recycle gas stream. This type of process is described, for example in EP 89691; U.S. 4,543,399; WO 94/25495 and U.S. 5,352,749, which are hereby incorporated by reference. A parη cularly preferred method of recycling the liquid to the bed is to separate the liquid from the recycle gas stream and to reinject this liquid directly into the bed, preferably using a method which generates fine droplets of the liquid within the bed. This type of process is described in BP Chemicals" WO 94/280322which is hereby incorporated by reference.
v The polymerizaη on reacη on occurring in the gas fluidized bed is catalyzed by the conη nuous or semi-conη nuous addiη on of the catalyst components of the catalyst system or of the catalyst system as a whole. In a highly desirable method of operaη on, the catalyst components are produced outside the reactor, the process comprising:
1) deposiη ng one or more metallocene complexes on individual metallocene support porη ons of the support material component or on a common metallocene support to form one or more individually supported metallocene complex components;

2) deposiη ng one or more cocatalysts on individual cocatalyst support porη ons of the support material component or on a common cocatalyst support to form one or more individually supported cocatalyst components; and
3) combining together in any order one or more of the metallocene components from 1) and the cocatalyst components from 2) to form the catalyst system prior to introducη on of the catalyst system into the reactor; or
4) introducing one or more of the individually supported metallocene components from 1) and the individually supported cocatalyst components from 2) into the reactor individually. J
The polymer is produced directly in the fluidized bed by catalyzed copolymerizaη on of the monomer and one or more comonomers on the fluidized parη cles of catalyst, supported catalyst or prepolymer within the bed. Start-up of the polymerizaη on reacη on is achieved using a bed of preformed polymer parη cles, preferably similar to the target polyolefin, and condiη oning the bed by drying with inert gas or nitrogen prior to introducing the catalyst, the monomer(s) and any other gases which it is desired to have in the recycle gas stream, such as a diluent gas, hydrogen chain transfer agent, or an inert condensable gas when operaη ng in gas phase condensing mode. The produced polymer is discharged conη nuously or disconη nuously from the fluidized bed as desired. Such processes are used commercially on a large scale for the manufacture of high density polyethylene (HDPE), medium density polyethylene (MDPE), linear low density polyethylene (LLDPE) and polypropylene.
The gas phase processes suitable for the pracη ce of this invenη on are preferably conη nuous processes which provide for the conη nuous supply of reactants to the reacη on zone of the reactor and the removal of products from the reacη on zone of the reactor, thereby providing a steady-state environment on the macro scale in the reacη on zone of the reactor.
Typically,Vthe fluidized bed of the gas phase process is operated at temperatures
"■ " -" greater than 50°C, preferably, greater than about 60°C and from about 60°C to about 110°C, more preferably, greater than about 70°C and from about 70°C to about 110°C, even more preferably, greater than about 80°C. )

Typically the molar raη o of comonomer to monomer used in the polymerizaη on depeMs upon the desired density for the composiη on being produced and is about 0.5 or less. Desirably, where the polymerizaη on is a copolymerizaη on of ethylene or propylene as the monomer and of one or more a-olefm comonomers, the process of this invenη on employs a comonomer to monomer molar raη o which is less than 0.1, preferably less than 0.05, and more preferably less than 0.01.
For many polymerizaη ons where it is desirable to use hydrogen as a chain transfer agent, it is desirable that the polymerizaη on reactor contain hydrogen in a hydrogen to monomer molar raη o which is less than 0.05, preferably less than 0.02, more preferably less than 0.01.
Desirably, when producing polymers with a density range of from about 0.85 to about 0.98, the comonomer to monomer molar raη o is less than 0.1, the hydrogen to monomer raη o is less than 0.05, and the composiη on is produced in a reactor with a reacη on zone having a temperature of 70°C or higher.
Desirably, when producing polymers with a density range of from about 0.910 to about 0.925, the comonomer to monomer molar raη o is less than 0.02, the hydrogen to monomer raη o is less than 0.02, and the composiη on is produced in a reactor with a reacη on zone having a temperature of 70°C or higher.
Desirably, when producing materials with a density range of from about 0.91 to about 0.93 the comonomer to monomer raη o is less than 0.2, preferably less than 0.05, even more preferably less than 0.02, and may even be less than 0.01. Typically, the raη o of hydrogen to monomer is less than about 0.5, preferably less than 0.2, more preferably less than 0.05, even more preferably less than 0.02 and may even be less than 0.01.
The above-described ranges of process variables are appropriate for the gas phase process of this invenη on and may be suitable for other processes adaptable to the 2pracη ce of this invenη on.
A number of patents and patent applicaη ons describe gas phase processes which are adaptable for use in the process of this invenη on, parη cularly, U.S. Patents 2 4,588,790; 4,543,399; 5,352,749; 5,436,304; 5,405,922; 5,462,999; 5,461,123; 5,453,471; 5,032,562; 5,028,670; 5,473,028; 5,106,804; 5,556,238; 5,541,270; ■

5,608,019; 5,616,661; and EP applicaη ons 659,773; 692,500; 780,404; 697,420; 628,343; 593,083; 676,421; 683,176; 699,212; 699,213; 721,798; 728,150; 728,151; 728,771; 728,772; 735,058; and PCT Applicaη ons WO 94/29032; WO 94/25497; WO 94/25495; WO 94/28032; WO 95/13305; WO 94/26793; WO 95/07942; WO 97/25355; WO 93/11171; WO 95/13305; and WO 95/13306, all of which are hereby incorporated herein by reference. >
The skilled arη san will appreciate that the invenη on disclosed herein may be pracη ced in the absence of any component which has not been specifically disclosed. The following examples are provided in order to further illustrate the invenη on and are not to be construed as limiη ng. Unless stated to the contrary, all parts and percentages are expressed on a weight basis.
Experimental
The polymerizaη on examples which follow were carried out in a 13 liter gas phase reactor having a four inch diameter thirty inch long fluidizaη on zone and an eight inch diameter ten inch long velocity reducη on zone which are connected by a transiη on secη on having tapered walls. Typical operaη ng ranges are 40 to 100°C, 250 to 350 psia total pressure and up to 8 hours reacη on η me. Ethylene, comonomer, hydrogen and nitrogen enter the bottom of the reactor where they pass through a gas distributor plate. The flow of the gas is 2 to 8 η mes the minimum parη cle fluidizaη on velocity rFluidizaη on Engineering. 2nd Ed., D. Kunii and O. Levenspiel, 1991, Butterworth-Heinemann]. Most of the suspended solids disengage in the velocity reducη on zone. The reactant gases exit the top of the velocity reducη on zone and pass through a dust filter to remove any fines. The gases then pass through a gas booster pump. The polymer is allowed to accumulate in the reactor over the course of the reacη on. The total system pressure is kept constant during the reacη on by regulaη ng the flow of monomer into the reactor. Polymer is removed from the reactor to a recovery vessel by opening a valve located at the bottom of the fluidizaη on zone. The polymer recovery vessel is kept at a lower pressure than the reactor. The pressures of ethylene, comonomer and hydrogen reported refer to parη al pressures.
The mode of reactor operaη on which was employed is referred to as semi-batch. The catalyst was prepared and loaded into a catalyst injector in an inert

atmosphere glovebox. The injector was removed from the glovebox and inserted into the top of the reactor. Appropriate amounts of ethylene, 1-butene, hydrogen and nitrogen were introduced into the reactor to bring the total pressure to 300 psia. The catalyst was then injected and the polymer was usually allowed to form for 30 minutes. The total system pressure was kept constant during the reacη on by regulaη ng the flow of monomer into the reactor. After 30 minutes the reactor was empη ed and the polymer powder was collected.
Several different silica pretreatment procedures were used. One pretreatment procedure involved first drying approximately 2 grams of the silica under a nitrogen purge at 200°C for several hours. The silica was removed from the drying oven and mixed with a quanη ty of disη lled water equal to 3 weight percent of the silica. The silica containing the water was shaken for about ten minutes to disperse the water evenly and to break up the lumps which formed on addiη on of the water. The silica was then brought into an inert atmosphere glovebox where in a toluene slurry it was then treated with triethyl aluminum (TEA) in a amount corresponding to an AI/H2O molar raη o of 2/1. The silica was then filtered and washed several η mes with toluene to remove any residual soluble aluminum compounds which may have resulted during the dehydraη on step. The supports were then dried under reduced pressure to give a free flowing powder.
A second pretreatment procedure involved first drying approximately 5 grams of the silica under a nitrogen purge at 500°C for 4 hours. The silica was removed from the drying furnace and brought into an inert atmospheric glovebox where in a toluene slurry it was treated with TEA in an amount corresponding to an Al/OH raη o of 1/1. This corresponded to a TEA/silica raη o of 1.2 mmoles TEA/g silica. The silica was then filtered and washed several η mes with toluene to remove any residual soluble aluminum compounds which may have resulted during the dehydraη on step. The supports were then dried under reduced pressure to give a free flowing powder.
Preparaη on of a typical supported catalyst involved first preparing 0.005 M soluη ons of (T|5-C5Me4SiMe2NCMe3)η (Me2) and of (T)5-C5Me4SiMe2NCMe3)η (s-trans- n.4-l,4-trans, trans-diphenyl-l,3-butadiene) and of (η 5-C5Me4SiMe2NCMe3)-η (ri4-C5H8) catalyst and borane ([B(C6F5)3l) cocatalyst
in toluene. An appropriate amount (typically 100 to 300 ul) of toluene was added to the silica to pre-wet the support. An appropriate amount of the metallocene catalyst was then added to the silica followed by addition of an appropriate amount of the cocatalyst. The solvents were then removed under vacuum from the agitated slurry to give the catalyst as a free-flowing powder.
Example 1
Catalyst support preparation
2 Grams of Davison type 948 silica was heated at 200°C for 4 hours in an inert stream of nitrogen. The silica was removed from the drying oven and mixed with 60 mg of distilled water (3 weight percent based on silica). The silica containing the water was shaken for about ten minutes to disperse the water evenly and to break up the lumps which formed on addition of the water. The silica was transferred into an inert atmosphere glovebox where it was then treated with TEA. The silica was suspended in an amount of dry toluene followed by the slow addition of 855 mg of TEA. The amount of TEA which was added corresponded to a water/TEA ratio of 1/2. The silica was then washed several times with toluene to remove any residual soluble aluminum compounds which may have resulted during the TEA treatment step. •
An aliquot (480 ul) of a 0.005 M solution (2.4 umol) of (TI5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.005 grams of the pretreated Davison 948 silica described above which had already been prewetted with -200 ul of dry toluene. An aliquot (480 ul) of a 0.005 M solution (2.4 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder.
Polymerization
The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, a hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 79 °C. No exotherm was measured upon injection of the catalyst into the reactor. 3.7 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.

in toluene. An appropriate amount (typically 100 to 300 ul) of toluene was added to the silica to pre-wet the support. An appropriate amount of the metallocene catalyst was then added to the silica followed by addition of an appropriate amount of the cocatalyst. The solvents were then removed under vacuum from the agitated slurry to give the catalyst as a free-flowing powder.
Example 1
Catalyst support preparation
2 Grams of Davison type 948 silica was heated at 200°C for 4 hours in an inert stream of nitrogen. The silica was removed from the drying oven and mixed with 60 mg of distilled water (3 weight percent based on silica). The silica containing the water was shaken for about ten minutes to disperse the water evenly and to break up the lumps which formed on addition of the water. The silica was transferred into an inert atmosphere glovebox where it was then treated with TEA. The silica was suspended in an amount of dry toluene followed by the slow addition of 855 mg of TEA. The amount of TEA which was added corresponded to a water/TEA ratio of 1/2. The silica was then washed several times with toluene to remove any residual soluble aluminum compounds which may have resulted during the TEA treatment step. ■
An aliquot (480 ul) of a 0.005 M solution (2.4 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.005 grams of the pretreated Davison 948 silica described above which had already been prewetted with -200 ul of dry toluene. An aliquot (480 ul) of a 0.005 M solution (2.4 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder.
Polymerization
The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, a hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 79 °C. No exotherm was measured upon injection of the catalyst into the reactor. 3.7 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.

Example 2
An aliquot (960 ul) of a 0.005 M solution (4.8 umol) of (r\5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.01 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1920 ul) of a 0.005 M solution (9.6 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 81 °C. No exotherm was measured upon injection of the catalyst into the reactor. 3.7 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.
Example 3
An aliquot (600 ul) of a 0.005 M solution (3.0 umol) of (t|5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.01 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1,800 ul) of a 0.005 M solution (9.0 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1 -butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 77 °C. A 4 °C was measured upon injection of the catalyst into the reactor. 6.3 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.
Example 4
An aliquot (400 ul) of a 0.005 M solution (2.0 umol) of (t|5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.01 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1,200 ul) of a 0.005 M solution (6.0 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added

to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 78 °C. No exotherm was measured upon injection of the catalyst into the reactor. 2.4 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.
Example 5
An aliquot (1,000 ul) of a 0.005 M solution (5.0 umol) of (r|5. C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.05 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1,250 ul) of a 0.005 M solution (6.25 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 82 °C. No exotherm was measured upon injection of the catalyst into the reactor. 11.8 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.
Example 6
An aliquot (600 ul) of a 0.005 M solution (3.0 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.05 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1800 ul) of a 0.005 M solution (9.0 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 80 °C. No exotherm was measured upon injection of the catalyst into the reactor. 9.4 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.

Example 7
An aliquot (600 ul) of a 0.005 M solution (3.0 umol) of (T\$-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.10 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1,800 ul) of a 0.005 M solution (9.0 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 80 °C. A 4 °C exotherm was measured upon injection of the catalyst into the reactor. 35.2 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.
Example 8
An aliquot (200ul) of a 0.005 M solution (1.0 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(Me2) in toluene was combined with 0.10 grams of Crosfield ES70Y silica which had been pretreated in a manner similar to Davison 948 in the previous example. The 0.10 grams of ES70Y silica was prewetted with -200 ul of dry toluene. An aliquot (200 ul) of a 0.005 M solution (1.0 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 70 °C. 14.1 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 2.
Example 9
Catalyst/support preparation
5 Grams of Davison type 948 silica was heated at 150°C for 16 hours. The silica was removed from the drying oven and mixed with 125 ml of toluene. To the slurry was added 1.25 ml of TEA. After reacting for 15 minutes the mixture was filtered, washed with about 50 ml toluene, then dried under vacuum. The amount of TEA which was added corresponded to a TEA/silica ratio of 0.25 ml TEA/g silica.

An aliquot (400 ul) of a 0.005 M solution (2.0 umol) of (n.5. C5Me4SiMe2NCMe3)-Ti(s-trans- n,4-l,4-trans, trans-diphenyl-l,3-butadiene) in toluene was combined with 0.005 grams of the pretreated Davison 948 silica described above which had already been prewetted with -200 ul of dry toluene. An aliquot (1,200 ul) of a 0.005 M solution (6.0 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder.
Polymerization
The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 64 °C. No exotherm was measured upon injection of the catalyst into the reactor. 9.9 Grams of polymer were recovered after 95 minutes. The results of this run are shown in Table 3.
Example 10
An aliquot (1000 ul) of a 0.005 M solution (5.0 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(r]4-C5H8) in toluene was combined with 0.05 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1250 ul) of a 0.005 M solution (6.25 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1 -butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 82 °C. No exotherm was measured upon injection of the catalyst into the reactor. 11.8 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 11
An aliquot (920 ul) of a 0.005 M solution (4.6 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(r|4-C5H8) in toluene was combined with 0.1 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1020 ul) of a 0.005 M solution (5.1 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent

was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 80 °C. A 4 °C exotherm was measured upon injection of the catalyst into the reactor. 20.4 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 12
An aliquot (200 ul) of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(r|4-C5H8) in toluene was combined with 0.03 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (600 ul) of a 0.005 M solution (3 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 79 °C. A 2 °C exotherm was measured upon injection of the catalyst into the reactor. 4.6 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 13
An aliquot (160 ul) of a 0.005 M solution (0.8 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(r|4-C5H8) in toluene was combined with 0.035 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (180 ul) of a 0.005 M solution (0.9 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 76 °C. No exotherm was measured upon injection of the catalyst into the reactor. 11.7 Grams of polymer were recovered after 26 minutes. The results of this run are shown in Table 3.

Example 14
An aliquot (400 ul) of a 0.005 M solution (2 umol) of (n5-C5Me4SiMe2NCMe3)-Ti0i4-C5H8) in toluene was combined with 0.1 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (1200 ul) of a 0.005 M solution (6 Umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 76 °C. A 2 °C exotherm was measured upon injection of the catalyst into the reactor. 27.7 Grams of polymer were recovered after 21 minutes. The results of this run are shown in Table 3.
Example 15
An aliquot (120 ul) of a 0.005 M solution (0.6 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(ri4-C5H8) in toluene was combined with 0.05 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (140 ul) of a 0.005 M solution (0.7 Umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 71 °C. No exotherm was measured upon injection of the catalyst into the reactor. 18.3 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 16
An aliquot (200 ul) of a 0.005 M solution (1 umol) of (T\5-C5Me4SiMe2NCMe3)-Ti(r|4-C5H8) in toluene was combined with 0.1 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (600 ul) of a 0.005 M solution (3 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the

semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 77 °C. A 3 °C exotherm was measured upon injection of the catalyst into the reactor. 48.8 Grams of polymer were recovered after 16.4 minutes. The results of this run are shown in Table 3.
Example 17
An aliquot (160 ul) of a 0.005 M solution (0.8 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(ii4-C5H8) in toluene was combined with 0.1 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (180 ul) of a 0.005 M solution (0.9 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 78 °C. An 8 °C exotherm was measured upon injection of the catalyst into the reactor. 41.6 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 18
An aliquot (160 ul) of a 0.005 M solution (0.8 umol) of (r|5-C5Me4SiMe2NCMe3)-Ti(ri4-C5H8) in toluene was combined with 0.4 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (180 ul) of a 0.005 M solution (0.9 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 76 °C. A 3 °C exotherm was measured upon injection of the catalyst into the reactor. 29.4 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 19
Catalyst/support preparation

5 Grams of Sylopol type 948 silica were heated at 500°C for 4 hours in an inert stream of nitrogen. The silica was transferred to an inert atmosphere glovebox where it was then treated with TEA. The silica was suspended in an amount of dry toluene followed by the slow addition of 684 mg of TEA. The amount of TEA which was added corresponded to a TEA/silica ratio of 1.2 mmoles/g silica. The silica was then washed several times with toluene to remove any soluble aluminum compounds.
An aliquot (200 ul) of a 0.005 M solution (1 umol) of (n.5-C5Me4SiMe2NCMe3)-Ti(ri4-C5H8) in toluene was combined with 0.10 grams of the pretreated Sylopol 948 silica described above which had already been prewetted with -200 ul of dry toluene. An aliquot (200 ul) of a 0.005 M solution (1.0 ul) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder.
Polymerization
The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the run was 72°C. No exotherm was measured upon injection of the catalyst into the reactor. 24.1 Grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 3.
Example 20
An aliquot (200 ul) of a 0.005 M solution (1 umol) of (n.5-C5Me4SiMe2NCMe3)-Ti(rt4-C5H8) in toluene was combined with 0.10 grams of the pretreated Sylopol 948 silica described above in Example 19 which had already been prewetted with -200 ul of dry toluene. An aliquot (200 ul) of a 0.005 M solution (1 umol) of (Ci 8H37)2(CH3)NH(C6F5)4 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 70 °C. A 4 °C exotherm was measured upon injection of the catalyst into the reactor.




Example 21
An aliquot (154 ul) of a 0.005 M solution (0.8 umol) of (r^-C5Me4SiMe2NCMe3)-Ti(r|4-C5H8) in toluene was combined with 0.1 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (176 ul) of a 0.005 M solution (0.9 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst formulation was 8.0 mmol Ti/g silica with a cocatalyst/catalyst ratio =1.1. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 76 °C. A 4°C exotherm was measured upon injection of the catalyst into the reactor. 25.5 Grams of polymer were recovered after 7 minutes. The results of this run are shown in Table 4.

Example 22
An aliquot (308 ul) of a 0.005 M solution (1.5 umol) of (TI5-C5Me4SiMe2NCMe3)-Ti(ri4-C5H8) in toluene was combined with 0.2 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (352 ul) of a 0.005 M solution (1.8 umol) of B(C6F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst formulation was 7.5 mmol Ti/g silica with a cocatalyst/catalyst ratio = 1.2. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 75 °C. A 10°C exotherm was measured upon injection of the catalyst into the reactor. 37.9 Grams of polymer were recovered after 5 minutes. The results of this run are shown in Table 4.
Example 23
An aliquot (193 ul) of a 0.005 M solution (1.0 umol) of (n5-C5Me4SiMe2NCMe3)-Ti(r|4-C5H8) in toluene was combined with 0.1 grams of the pretreated Davison 948 silica described above in Example 1 which had already been prewetted with -200 ul of dry toluene. An aliquot (578 ul) of a 0.005 M solution (3.0 umol) of B(C(>F5)3 in toluene was then added to the slurried silica. The solvent was removed to give a free-flowing powder. The catalyst formulation was 10 mmol Ti/g silica with a cocatalyst/catalyst ratio = 3. The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 77 °C. A 4°C exotherm was measured upon injection of the catalyst into the reactor. 29.6 Grams of polymer were recovered after 4.4 minutes. The results of this run are shown in Table 4.


Catalyst Preparations for Examples 24-26.
Preparation of Catalyst EG4. 17.0 kg of Crosfield ES70 silica (calcined at 500°C) were slurried in 110 liters of hexane, 25.8 liters of 0.989M TEA in hexane were added, and the slurry agitated for 2 hours at 30°C. The silica was allowed to settle, and the supernatent hexane removed. The silica was washed several times with hexane, until the concentration of Al in the washing had reached 3g of this TEA treated ES70 silica were slurried in 15 ml of dry toluene, 0.34 ml of a 7.85 weight percent solution of tris(pentafluorophenyl)boron in toluene were added. The mixture was shaken well, and then 0.025 g of rac [l,2-ethanediylbis(l-indenyl)]zirconium s-trans(ri4-trans,trans-l,4-diphenyl-l,3-butadiene) was added as a solid. The solvent was removed in vacuo at 25 °C to give a red powder, having good flowability.
Preparation of Catalyst EG6. 20.0 kg of Crosfield ES70 silica (calcined at 500°C) were slurried in 110 liters of hexane, 31.1 liters of 0.940M TEA in hexane were added, and the slurry agitated for 2 hours at 30°C. The silica was allowed to settle, and the supernatent hexane removed. The silica was washed several times with hexane, until the concentration of Al in the washing had reached 3g of this TEA treated ES70 silica were slurried in 15 ml of dry toluene, 0.69 ml of a 7.85 weight percent solution of tris(pentafluorophenyl)boron in toluene were added. The mixture was shaken well, and then 0.0 51 g of rac [ 1,2-ethanediylbis( 1 -

indenyl)]zirconium s-trans(t|4-trans,trans-l,4-diphenyl-l,3-butadiene) was added as a solid. The solvent was removed in vacuo at 25 °C to give a red powder, having good flowability.
Preparation of Catalyst PGD89. 100 g of the TEA treated ES70 silica described for EG6 were slurried in 350 ml of dry toluene. 11.30 ml of a 7.85 weight percent solution of tris(pentafiuorophenyl)boron in toluene were added. The mixture was shaken well, and then 0.845 g of rac-[l,2-ethanediylbis(l-indenyl)]zirconium s-trans(r]4-trans.trans-l,4-diphenyl-l,3-butadiene) was added as a solid. The solvent was removed in in vacuo at 35°C to give a pink/red powder, having good flowability.
Polymerization Tests
Example 24
324 g of NaCl was added to a 2.5 liter volume agitated dry phase reactor, which had been previously baked out at 85°C under a N2 purge, 0.944 g of a TEA treated silica was added to the reactor, and this was agitated for 15 minutes. The reactor was cooled to 70°C. and pressurized to 6.5 bar C2H4. Then 1-hexane was admitted to the reactor. A mixture of 0.230 g of catalyst Catalyst EG4 and 0.585 g of a TEA treated silica was injected into the reactor with high pressure N2. The temperature, C2H4 pressure and 1 -hexene levels were maintained constant during the rest of the test. The total polymerization time was 106 minutes. During the test, the average 1-hexane/C2H4 ratio was 0.0087. The reactor was vented and cooled, and 141 g of polymer was recovered after washing off the salt, giving an activity of 53.4g/g cat.h.bar. The polymer density was 0.920 g/ml and MI2.16 was 3-16- The bulk densitv of the powder was 0.37 g/ml. The results of this run are shown in Table 5.
Example 25
297 g of NaCl was added to a 2.5 liter volume agitated dry phase reactor, which had been previously baked out at 85°C under a N2 purge. 0.906 g of a TIBA treated silica was added to the reactor, and this was agitated for 15 minutes. The reactor was cooled to 70°C. and pressurized to 6.5 bar C2H4. Then 1-hexane was admitted to the reactor. A mixture of 0.219 g of catalyst Catalyst EG6 and 0.549 g of a TIBA treated silica was injected into the reactor with high pressure N2. The temperature, C2H4 pressure and 1 -hexene levels were maintained constant during the rest of the test. The

total polymerization time was 182 minutes. During the test, the average l-hexane/C2H4 ratio was 0.0085. The reactor was vented and cooled, and 194 g of polymer was recovered after washing off the salt, giving an activity of 44.9 g/g cat.h.bar. The polymer density was 0.922 g/ml and MI2.16 was 2.3 The bulk density of the powder was 0.37 g/ml. The results of this run are shown in Table 5.
Example 26
281 g of NaCl was added to a 2.5 liter volume agitated dry phase reactor, which had been previously baked out at 85°C under a N2 purge. 0.977 g of a TIBA treated silica was added to the reactor, and this was agitated for 15 minutes. The reactor was cooled to 70°C, and pressurized to 6.5 bar C2H4 Then 1-hexene was admitted to the reactor. A mixture of 0.204 g of catalyst Catalyst PGD89 and 0.646 g of a TIBA treated silica was injected into the reactor with high pressure N2. The temperature, C2H4 pressure and 1-hexane levels were maintained constant during the rest of the test. The total polymerization time was 88 minutes. During the test, the average 1 -hexane/C2H4 ratio was 0.0087. The reactor was vented and cooled, and 90 g of polymer was recovered after washing off the salt, giving an activity of 46.3 g/g cat.h.bar. The polymer density was 0.915 g/ml and M12.16 was 12.9. The bulk density of the powder was 0.39 g/ml. The results of this run are shown in Table 5.

Examples 27-31 Catalyst/Support Preparation
Approximately 50 g of Crosfield Type ES-70 silica were calcined in air at 500°C for four hours in a flowing stream of nitrogen. The silica was cooled to 200°C,

transferred to a 500 cc Schlenk flask with the Schlenk flask subsequently evacuated and transferred into an inert atmosphere glove box where the silica was treated with TEA. 20 g of the calcined silica were accurately weighed into a 200 cc Schlenk flask and enough hexane was added to make a slurry. 30.8 cc of 1 M TEA in hexane were added to the flask containing the slurried silica while swirling the flask by hand. After the addition of the TEA, the flask was allowed to stand, unagitated, for three hours. The treated silica was filtered, washed with several volumes of hexane and dried under vacuum at ambient temperature. 22.5 g of the TEA treated silica were recovered.
3 g of the treated silica were accurately weighed into each of five 100 cc Schlenk flasks. 15 cc of toluene were added to each flask to make a slurry. Aliquotes of a 0.025 M solution of Ethylene-bis-indenyl Zirconium Diphenylbutadiene (EBI-Zr-DPB) in toluene and a 0.10 M solution of borane in toluene were added to each flask and the solvent was removed under vacuum at ambient temperature while agitating each flask by hand. The nominal concentrations of EBI-Zr-DPB and FAB, in ^mol/g, for each catalyst formulation are given in Table 6.
Polymerization
In each of five separate runs, 0.1 g of the above catalyst were added to an agitated dry phase reactor (ADPR) which was under an ethylene pressure of 7.4 bar, a nitrogen pressure of 1 bar, and a 1-hexene pressure of 0.04 bar. The average temperature throughout the 90 minute polymerization runs was 70°C. The polymerization results are shown below in Table 6.


For Examples 32-45, the mass of silica support required to give the desired metallocene loading was divided into two equal portions, the catalyst was supported on one portion and the appropriate amount of cocatalyst was supported on the other portion. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for from 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the reactor.
Example 32
Supported Catalyst Preparation
2 grams of Davison type 948 silica was calcined at 500°C for 4 hours in an inert stream of nitrogen. The silica was transferred into an inert atmosphere glovebox where it was then treated with TEA. The silica was suspended in an amount of dry toluene followed by the slow addition of 2.4 mmoles of TEA. The amount of TEA which was added corresponded to a hydroxyl/TEA ratio of 1/1 (1.2 mmoles TEA/g silica). The silica was then washed several times with toluene to remove any residual soluble aluminum compounds.
200 ul of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(ri4-C5H8) in toluene was added to 0.1 grams of Davison 948 silica, which had been treated as described above, in 200 ul of dry toluene. The solvent was removed under reduced pressure to give a free-flowing powder.
Polymerization
The catalyst described above was added to the semi-batch gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 70 °C. No exotherm was measured upon injection of the catalyst into the reactor. 0.0 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 33
200 ul of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(n4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in

Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 100 ul of a 0.005 M solution (0.5 umol) of B(C6F5)3 in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 69 °C. No exotherm was measured upon injection of the catalyst into the reactor. 13.6 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 34
200 ul of a 0.005 M solution (1 umol) of (r|5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 200 ul of a 0.005 M solution (1 umol) of B(Q;F5)3 in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature upon injection of the catalyst was 66°C. The temperature increased 4°C during the first 5 minutes of polymerization then remained constant at 70°C for the duration of the run. 22.2 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 35
200 ul of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in

Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 200 ul of a 0.005 M solution (1 umol) of B(C6F5)3 in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 66°C followed by a 4°C exotherm. The temperature remained at 69°C for the duration of the polymerization. 25.5 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 36
200 ul of a 0.005 M solution (1 umol) of (r,5-C5Me4SiMe2NCMe3)- Ti(rj4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 400 ul of a 0.005 M solution (2 umol) of B(C6Fs)3 in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 67°C followed by a 2°C exotherm. The temperature increased an additional 4°C during the first 10 minutes of polymerization then decreased 4°C during the remaining 20 minutes. 36.0 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 37
200 ul of a 0.005 M solution (1 umol) of (r|5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in

Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The catalyst was loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1 -butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature remained steady at 70°C throughout the polymerization. 0.0 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 38
400 ul of a 0.005 M solution (2 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(T»4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 100 ul of a 0.005 M solution (0.5 umol) of B(Q;F5)3 in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 68°C followed by a 2°C exotherm. The temperature remained steady at 70°C for the during of the polymerization. 8.8 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 39
200 ul of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(ri4-C5H8) in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 50 ul of a 0.005 M solution (0.25 umol) of B(C6F5)3 in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas

phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 68°C followed by a 1 °C exotherm. The temperature remained steady at 69°C for the during of the polymerization. 4.0 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 40
200 ul of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 100 ul of a 0.005 M solution (0.5 umol) of B(C6F5)3 in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 68°C followed by a 2°C exotherm. The temperature increased to 74°C over the next 10 minutes then decreased to 69°C over the last 20 minutes. 9.0 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 41
400 ul of a 0.005 M solution (2 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 400 ul of a 0.005 M solution (2 umol) of B(C6F5)3 in toluene was added to 0.05 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of

5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 66°C. The temperature increased to 74°C over the next 11. 5.5 grams of polymer were recovered after 11 minutes. The results of this run are shown in Table 7.
Example 42
200 ul of a 0.005 M solution (1 umol) of (n5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 200 ul of a 0.005 M solution (1 umol) of B(C6Fs)3 in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The catalyst was injected at 70°C followed by a 2°C exotherm. The temperature remained steady at 72°C for the during of the polymerization. 11.1 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 43
200 ul of a 0.005 M solution (1 umol) of (r|5-C5Me4SiMe2NCMe3)- Ti(r)4-C5H8) in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 400 ul of a 0.005 M solution (2 umol) of B(C6Fs)3 in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The

temperature throughout the polymerization was 71 °C. No exotherm was measured upon injection of the catalyst into the reactor. 10.5 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 44
200 ul of a 0.005 M solution (1 umol) of (rj5-C5Me4SiMe2NCMe3)- Ti(r)4-C5H8) in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The catalyst was loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature remained steady at 68°C throughout the polymerization. 0.0 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.
Example 45
400 ul of a 0.005 M solution (2 umol) of (r|5-C5Me4SiMe2NCMe3)- Ti(r|4-C5H8) in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. 400 ul of a 0.005 M solution (2 umol) of B(Q)F5)3 in toluene was added to 0.025 grams of the pretreated silica described in Example 32 in 200 ul of dry toluene. The solvent was removed to give a free-flowing powder. The two portions of catalyst-containing silica and cocatalyst-containing silica, each of which was a free-flowing powder, were then mixed together and vigorously shaken for 5 to 10 seconds. The mixture was then loaded into a catalyst injector and injected into the semi-batch, gas phase reactor which was under an ethylene pressure of 240 psi, a 1-butene pressure of 5.4 psi, an hydrogen pressure of 1.3 psi and a nitrogen pressure of 53 psi. The temperature throughout the polymerization was 69 °C. No exotherm was measured upon injection of the catalyst into the reactor. 18.3 grams of polymer were recovered after 30 minutes. The results of this run are shown in Table 7.




WE CLAIM:
1. A process for the polymerization of an olefin monomer, or of an olefin monomer
and one or more comonomers, to produce a polymer, the process carried out in a
polymerization reactor in the presence of a supported olefin polymerization catalyst
system produced from catalyst components comprising:
1) a support material component comprising one or more dehydrated support
materials;
2) a metallocene complex component comprising one or more metallocene complexes used in a total loading range of from 0.1 to 25 umol of metallocene complex /gram of support material component;
3) an activator component comprising one or more activators used in a range of molar ratios of total moles of activator to total moles of metallocene complex of from 0.5 to a 2.5;
where the catalyst system is used at a catalyst concentration in the range of from 0.01 to 6 moles of active catalyst/mole of monomer, and a catalyst efficiency results that is at least 2.4 x 10 g polymer/g mol catalyst/hour.
2. The process for the polymerization of an olefin monomer, or of an olefin monomer
and one or more comonomers, to produce a polymer, the process carried out in a
polymerization reactor in the presence of a supported olefin polymerization catalyst
system produced from catalyst components comprising:
1) a support material component comprising one or more dehydrated support
materials;
2) a metallocene complex component comprising one or more metallocene complexes
all of which have as a central metal Ti used in a total loading range of from 0.1 to 25
umol of metallocene complex/gram of support material component;

3) an activator component comprising one or more activators used in a range of molar ratios of total moles of activator to total moles of metallocene complex of from 0.5 to 2.5; where a catalyst efficiency results that is at least 0.5 x 106 g polymer/g catalyst/hour.
3. A process for the polymerization of an olefin monomer, or of an olefin monomer
and one or more comonomers, to produce a polymer, the process carried out in a
polymerization reactor in the presence of a supported olefin polymerization catalyst
system produced from catalyst components comprising:
1) a support material component comprising one or more dehydrated support
materials;
2) a metallocene complex component comprising one or more metallocene complexes having as a central metal Ti in which the formal oxidation state is +2 used in a total loading range of from 0.1 to 25 umol of metallocene complex/gram of support material component;
3) an activator component where a catalyst efficiency results that is at least 0.5 x 16 g polymer/g catalyst/hour;

4. The process as claimed in one of claims 1-3, wherein the metallocene complex component is used in a loading range of from 0.3 to 20 umol/gram of support material component.
5. The process as claimed in claim 4, wherein the metallocene complex component is used in a loading range of from 1 to 20 umol/gram of support material component.
6. The process as claimed in one of claims 1-5, wherein the activator component is used in a range of molar ratios to the metallocene complex component of from 1 to 2.

7. The process as claimed in claim 6, wherein the activator component is used in a range of molar ratios to the metallocene complex component of from 1 to 1.5.
8. The process as claimed in claim 1, wherein the catalyst system is used in the reactor at a catalyst concentration in the range of 0.02 to 3 moles of active catalyst/mole of monomer.
9. The process as claimed in claim 8, wherein the catalyst system is used in the reactor at a catalyst concentration in the range of 0.05 to 3 moles of active catalyst/mole of monomer.

10. The process as claimed in claim 9, wherein the catalyst system is used in the reactor at a catalyst concentration in the range of 0.1 to 0.3 ug active catalyst/g monomer.
11. The process as claimed in one of claims 1-10, wherein the catalyst efficiency is greater than 4.8 x 17 g polymer/mole catalyst/hour.
12. The process as claimed in claim 11, wherein the catalyst efficiency is greater than 9.6 x 107 g polymer/mole catalyst/hour.
13. The process as claimed in claim 12, wherein the catalyst efficiency is greater than 14.4 x 107 g polymer/mole catalyst/hour.
14. The process as claimed in claim 13, wherein the catalyst efficiency is greater than 24 x 107 g polymer/mole catalyst/hour.

15. The process as claimed in one of claims 1-14, wherein the metallocene complex component has been produced with a mono-Cp metallocene complex.
16. The process as claimed in claim 15, wherein the metallocene complex component has been produced with a metallocene complex of the formula:

wherein:
M is titanium or zirconium in the +2 formal oxidation state;
L is a group containing a cyclic, delocalized anionic, ^-system through which the group is bound to M, and which group is also bound to Z;
Z is a moiety bound to M via a X is a neutral, conjugated or nonconjugated diene, optionally substituted with one or more groups selected from hydrocarbyl or trimethylsilyl groups, said X having up to 40 carbon atoms and forming a it-complex with M.
17. The process as claimed in claim 1 or claim 2, wherein the mono-Cp metallocene
complex has as a central metal Ti in which the formal oxidation state is +3 or +4.
18. The process as claimed in claims 1-14, wherein the metallocene complex
component has been produced with a bis-Cp metallocene complex.

19. The process as claimed in claim 18, wherein the metallocene complex component has been produced with a bridged bis-Cp metallocene complex.
20. The process as claimed in claim 19, wherein the metallocene complex component has been produced with a metallocene complex of the formula:
wherein
Cp1, Cp2 are independently a substituted or unsubstituted indenyl or hydrogenated
indenvlgroup;
Y is a univalent anionic ligand, or Y is a diene;
M is zirconium, titanium or hafnium: and
Z is a bridging group comprising an alkylene group having 1 to 20 carbon atoms or a
dialkylsilyl or dialkylgermyl group, or alkyiphosphine or alkylamine radical.
21. The process as claimed in claims 1-20, wherein the metallocene complex
component has been produced with a single metallocene complex.
22. The process as claimed in one of claims 1-20, wherein the metallocene complex
component has been produced with two or more metallocene complexes, or has been
produced with at least one metallocene complex and at least one nonmetallocene
catalyst, or wherein the catalyst system has been produced with metallocene complex
components from at least two of claims 1-3.
i

23. The process as claimed in claim one of claims 1-22, wherein the support material component comprises a polymer, an inorganic oxide, a metal halide, a prepolymerized polymeric substrate or a mixture thereof.
24. The process as claimed in claim 23, wherein the support material component comprises an inorganic oxide.
25. The process as claimed in claim 24, wherein the support material component comprises silica, alumina, silica-alumina, or a mixture thereof.
26. The process as claimed in claim 25, wherein the support material component comprises silica, alumina, silica-alumina, or a mixture thereof which has been modified with Ti02, Zr02, Ge02, B203, or a mixture thereof.
27. The process as claimed in claim 23, wherein the support material component comprises a polymer.
28. The process as claimed in claim one of claims 1-27, wherein the activator component comprises a cocatalyst.
29. The process as claimed in claim 28, wherein the cocatalyst is
tris(pentafluorophenyl)borane, N-R3,N-R4 anilinium tetrakis(pentafluorophenyl)borate
where R3 and R4 independently each occurrence are substituted or unsubstituted
saturated hydrocarbyl groups having from 1 to 8 carbon atoms,
(R1R2NHCH3)+(C6H4OH)B(C6F5)3-, or (R,R2NHCH3)+ B(C6F5)4", where R, and R2
independently each occurrence are substituted or unsubstituted saturated hydrocarbyl
groups having from 12 to 30 carbon atoms.

30. The process as claimed in one of claims 1-29, wherein the catalyst system has been produced so that it contains alumoxane in a nonactivating concentration.
31. The process as claimed in one of claims 1-29, wherein the catalyst system has been produced so that it is essentially alumoxane-free.
32. The process as claimed in one of claims 1-31, wherein one or more of the catalyst components or the catalyst system as a whole has been prepolymerized.
33. The process as claimed in one of claims 1-32, wherein ethylene is the monomer and the comonomer is propene, 1-butene, 1-pentene, 4-methyl-l-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1,7-octadiene, 1,5-hexadiene, 1,4-pentadiene, 1,9-decadiene, ethylidenenorbornene, styrene, methylstyrene, or a mixture thereof.
34. The process as claimed in one of claims 1-32, wherein propene is the monomer and the comonomer is ethylene, 1-butene, 1-pentene, 4-methyl-l-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1,7-octadiene, 1,5-hexadiene, 1,4-pentadiene, 1,9-decadiene, ethylidenenorbornene, styrene, methylstyrene, or a mixture thereof.
35. The process as claimed in one of claims 1-34, wherein the process is a continuous process conducted in a single gas phase reactor.
36. The process as claimed in claim 35, wherein the process is conducted in gas phase reactor operating in condensed mode.
37. The process as claimed in one of claims 1-34, wherein the process is a continuous process conducted in a single slurry reactor.

38. The process as claimed in one of claims 1-34, wherein the process is carried out in two or more reactors, optionally in the presence of one or more additional metallocene or nonmetallocene catalyst systems.
39. The process as claimed in one of claims 1-38, wherein the polymer is produced in a reactor with a reaction zone having a temperature of 60°C or higher.
40. The process as claimed in claim 39, wherein the polymer is produced in a reactor with a reaction zone having a temperature of 70°C or higher.
41. The process as claimed in claim 40, wherein the polymer is produced in a reactor with a reaction zone having a temperature of 80°C or higher.
42. The process as claimed in one of claims 1-41, wherein the polymerization is a copolymerization of ethylene or propylene as the monomer and of one or more a-olefin comonomers at a comonomer to monomer molar ratio which is less than 0.1.

43. The process as claimed in claim 42, wherein the polymerization is a copolymerization of ethylene or propylene as the monomer and of one or more a-olefin comonomers at a comonomer to monomer molar ratio which is less than 0.05.
44. The process as claimed in claim 43, wherein the polymerization is a copolymerization of ethylene or propylene as the monomer and of one or more a-olefin comonomers at a comonomer monomer molar ratio which is less than 0.02.
45. The process as claimed in one of claims 1-44, wherein the polymerization reactor
contains hydrogen in a hydrogen to monomer molar ratio which is less than 0.05.

46. The process as claimed in claim 45, wherein the polymerization reactor contains hydrogen in a hydrogen to monomer molar ratio which is less than 0.02.
47. The process as claimed in claim 46, wherein the polymerization reactor contains hydrogen in a hydrogen to monomer molar ratio which is less than 0.01.
48. The process as claimed in one of claims 1-47, wherein the density of the polymer is from 0.85 to 0.98, the comonomer to monomer molar ratio is less than 0.1, the hydrogen to monomer ratio is less than 0.05, and the composition is produced in a reactor with a reaction zone having a temperature of 70°C or higher.
49. The process as claimed in claim 48, wherein the density of the polymer is from 0.910 to 0.925, the comonomer to monomer molar ratio is less than 0.02, the hydrogen to monomer ratio is less than 0.02, and the composition is produced in a reactor with a reaction zone having a temperature of 70°C or higher.
50. The process as claimed in one of claims 1-49, wherein the catalyst system is produced outside the reactor by combining the catalyst components in any order by either a wet impregnation method or a dry impregnation method.
51. The process as claimed in one of claims 1-50, wherein the catalyst components are produced outside the reactor, the process comprising:
1) depositing one or more metallocene complexes on individual metallocene support portions of the support material component or on a common metallocene support to form one or more individually supported metallocene complex components;

2) depositing one or more cocatalysts on individual cocatalyst support portions of the support material component or on a common cocatalyst support to form one or more individually supported cocatalyst components: and
3) combining together in any order one or more of the metallocene components from 1) and the cocatalyst components from 2) to form the catalyst system prior to introduction of the catalyst system into the reactor; or
4) introducing one or more of the individually supported metallocene components from 1) and the individually supported cocatalyst components from 2) into the reactor individually.
52. A process for maximizing the efficiency of a catalyst system for the polymerization of an olefin monomer, or of an olefin monomer and one or more comonomers, to produce a polymer, the process carried out in a polymerization reactor in the presence of a supported olefin polymerization catalyst system produced from catalyst components comprising:
1) a support material componentcomprising one or more dehydrated support materials:
2) a metallocene complex component: and
3) an activator component:
wherein the metallocene complex component is used in a loading range, in terms of mass of metallocene complex component relative to the mass of support material component, the activator component is used in a range of molar ratios of the activator component to the metallocene complex component, and the catalyst system is used in a range of catalyst concentrations, in a balanced manner to maximize the catalyst efficiency in terms of mass of polymer produced per mass of catalyst per hour.

53. A supported olefin polymerization catalyst system produced from catalyst
components comprising:
1) a support material componentcomprising one or more dehydrated support materials:
2) a metallocene complex component: and
3) an activator component:
20 where the metallocene complex component is used in a loading range of from 0.1 to 25 umol/gram of support material component, the cocatalyst or activator component is used in a range of molar ratios to the metallocene complex component of from 0.5 to 2.5, and, when the catalyst system is used in a reactor to polymerize one or more olefin monomers to produce a polymer, the catalyst system is used at a catalyst concentration in the range of 0.01 to 6 moles of active catalyst/mole of monomer, and a catalyst efficiency results that is at least 2.4 x 107 g polymer/mole of catalyst/hour.
54. A catalyst system comprising:
a) a metallocene component comprising one or more metallocene complexes
supported on individual metallocene supports or a common metallocene support; and
b) a cocatalyst component comprising one or more cocatalysts or activators supported
on individual cocatalyst supports or a common cocatalyst support, where at least one
of the cocatalysts or activators is a non-alumoxane nonionic cocatalyst or activator.
55. The catalyst system as claimed in claim 54, wherein each of the supports independently comprises a polymer, an inorganic oxide, a metal halide or a mixture thereof.
56. The catalyst system as claimed in claim 55, wherein one or more of the supports comprises an inorganic oxide.

57. The catalyst system as claimed in claim 56, wherein one or more of the supports
comprises silica, alumina, silica-alumina, or a mixture thereof.
58. The catalyst system as claimed in claim 57, wherein one or more of the supports comprises silica, alumina, silica-alumina, or a mixture thereof which has been modified with Ti02, Zr02, GeC>2, B2O3, or a mixture thereof.
59. The catalyst system as claimed in claim 54, wherein all of the cocatalysts or activators are non-alumoxane nonionic cocatalysts or activators.

Documents:

725-mas-98 abstract.pdf

725-mas-98 assignment.pdf

725-mas-98 claims duplicate.pdf

725-mas-98 claims.pdf

725-mas-98 correspondence others.pdf

725-mas-98 correspondence po.pdf

725-mas-98 description (complete) duplicate-1.pdf

725-mas-98 description (complete) duplicate.pdf

725-mas-98 description (complete)-1.pdf

725-mas-98 description (complete).pdf

725-mas-98 form-19.pdf

725-mas-98 form-2.pdf

725-mas-98 form-26.pdf

725-mas-98 form-4.pdf

725-mas-98 form-6.pdf

725-mas-98 others.pdf

725-mas-98 petition.pdf


Patent Number 202827
Indian Patent Application Number 725/MAS/1998
PG Journal Number 05/2007
Publication Date 02-Feb-2007
Grant Date 20-Oct-2006
Date of Filing 03-Apr-1998
Name of Patentee M/S. B P CHEMICALS LTD.
Applicant Address COMPASS POINT,79-87 KINGSTON ROAD,STAINES,MIDDLESEX TW18 IDT
Inventors:
# Inventor's Name Inventor's Address
1 KEVIN P.PEIL 4636 EIGHT MILE ROAD,AUBURN,MICHIGAN 48611
2 DAVID R. WISOA 1220 WEST STEWART ROAD,MIDLAND,MICHIGAN-48640
PCT International Classification Number C08F 004/54
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/042,638 1997-04-04 U.S.A.