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US20020160907A1 - Delayed activity supported olefin polymerization catalyst compositions and method for making and using the same - Google Patents

Delayed activity supported olefin polymerization catalyst compositions and method for making and using the same Download PDF

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Publication number
US20020160907A1
US20020160907A1 US09/978,704 US97870401A US2002160907A1 US 20020160907 A1 US20020160907 A1 US 20020160907A1 US 97870401 A US97870401 A US 97870401A US 2002160907 A1 US2002160907 A1 US 2002160907A1
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group
substituted
hydrocarbyl
aromatic
sir
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Edmund Carnahan
David Neithamer
Ravi Shankar
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BP Chemicals Ltd
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BP Chemicals Ltd
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Assigned to DOW CHEMICAL COMPANY THE reassignment DOW CHEMICAL COMPANY THE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NEITHAMER, DAVID R., SHANKAR, RAVI B., CARNAHAN, EDMUND M.
Publication of US20020160907A1 publication Critical patent/US20020160907A1/en
Priority to US10/880,582 priority patent/US7012121B2/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F10/02—Ethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/65916—Component covered by group C08F4/64 containing a transition metal-carbon bond supported on a carrier, e.g. silica, MgCl2, polymer

Definitions

  • Olefin polymerization catalysts used in gas phase processes are typically supported on a carrier in order to obtain a polymer of acceptable morphology.
  • the polymer particles will have low fines (defined as particles having a particle size ⁇ 125 ⁇ m) and low agglomerates (defined as particles having a particle size >1500 ⁇ m) and be of acceptable bulk density (>0.3 g/mL). While the high activity characteristic of metallocene and constrained geometry catalysts is advantageous from a productivity perspective, polymer morphology problems may result because the supported catalyst is at peak activity when it is injected into the reactor.
  • U.S. Pat. No. 5,693,727 discloses the addition of catalyst components into a reactor as a liquid spray. This patent provides that all or a portion of the co-catalyst can be fed separately from the metal compound(s) to the reactor. This patent does not exemplify supported catalysts.
  • U.S. Pat. No. 5,763,349 describes mixing a metallocene halide and a cocatalyst on a support. Subsequent addition of a metal alkyl was then employed to generate the active catalyst. U.S. Pat. No. 5,763,349 similarly teaches the introduction of a metal alkyl to the reactor to achieve activation.
  • WO 95/10542 discloses the addition of catalyst and cocatalysts supported separately on two different carriers. Prior to introduction into the reactor, the supported metallocene halide/cocatalyst have minimal if any catalytic activity, indicating that all activation occurs in the reactor. This technology relies upon in-reactor migration of either the metal complex or the cocatalyst from one particle to the other to achieve activation, which may lead to product morphology problems.
  • Ti(II) and Zr(II) diene complexes such as are disclosed in U.S. Pat. No. 5,470,993 (incorporated herein by reference in its entirety) can be activated by trispentafluorophenylborane or borate cocatalysts. These catalyst compositions often exhibit extremely high initial polymerization rates, high exotherms, and decaying reaction kinetic profiles in a batch reactor.
  • the subject invention provides a supported catalyst composition for use in the gas-phase polymerization of one or more a-olefins and methods for making and using the same, said catalyst composition comprising:
  • M is a metal from one of Groups 4 to 10 of the Periodic Table of the Elements, which is in the +2 or +4 formal oxidation state
  • Cp is a ⁇ -bonded anionic ligand group
  • Z is a divalent moiety bound to Cp and bound to M by either covalent or coordinate/covalent bonds, 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 neutral conjugated diene ligand group having up to 60 atoms, or a dianionic derivative thereof;
  • said catalyst composition is characterized as having an improved kinetic profile in a gas phase polymerization process.
  • the invention provides a supported catalyst composition as previously identified having a kinetic profile in a batch reactor, gas phase polymerization of one or more a-olefins that obeys the following relationship:
  • K r is the ratio of the cumulative net catalyst activity 30 minutes after onset of polymerization (A 30 ) divided by the cumulative net catalyst activity 90 minutes after onset of polymerization (A 90 ).
  • a 30 and A 90 are determined by calculating the grams polymer/gram supported catalyst composition ⁇ time (hr) ⁇ total monomer pressure (100 kPa).
  • the invention provides supported catalyst compositions and methods for making and using the same wherein the supported catalyst composition, when injected into a gas phase polymerization reactor, and contacted with one or more ⁇ -olefin monomers, demonstrates a K r which is at least 10 percent less than K* r , where K*, is the ratio of cumulative net catalyst activity for a comparative supported catalyst composition prepared using the metal complex (t-butylamido)dimethyl(tetramethylcyclo-pentadienyl)silanetitanium(II) 1,3-pentadiene and a cocatalyst comprising armenium (diethylaluminumoxyphenyl)tris-(pentafluorophenyl)borate.
  • K* is the ratio of cumulative net catalyst activity for a comparative supported catalyst composition prepared using the metal complex (t-butylamido)dimethyl(tetramethylcyclo-pentadienyl)silanetitanium(II) 1,
  • the subject invention provides a fully formulated supported constrained geometry catalyst composition which exhibits high productivity over an increased catalyst lifetime.
  • a metal complex with a suitable diene ligand in combination with an appropriate cocatalyst it has been found that, in contrast to known compositions which are characterized as exhibiting a high initial catalytic activity followed by a period of decreasing catalytic activity, the present compositions exhibit an improved kinetic profile over at least the first ninety minutes of polymerization.
  • the catalyst compositions may exhibit an initial catalyst activity that is less exothermic than for comparative catalyst compositions. Additionally, the catalyst activity may also increase over a longer period of time that for comparative catalyst compositions. Finally, the catalyst activity ultimately may decrease under batch reactor conditions at a rate that is less than that for comparative catalyst compositions.
  • Suitable metal complexes may be derivatives of any transition metal, preferably Group 4 metals that are in the +2, or +4 formal oxidation state.
  • Preferred compounds include constrained geometry metal complexes containing one ⁇ -bonded anionic ligand group, which may be cyclic or noncyclic delocalized ⁇ -bonded anionic ligand groups. Exemplary of such ⁇ -bonded anionic ligand groups are conjugated or nonconjugated, cyclic or non-cyclic dienyl groups, allyl groups, boratabenzene groups, and arene groups.
  • ⁇ -bonded is meant that the ligand group is bonded to the transition metal by means of delocalized electrons present in a ⁇ bond.
  • Each atom in the delocalized ⁇ -bonded group may independently be substituted with a radical selected from the group consisting of hydrogen, halogen, hydrocarbyl, halohydrocarbyl, Group 15 or 16 heteroatom-containing radicals, hydrocarbyl-substituted metalloid radicals wherein the metalloid is selected from Group 14 of the Periodic Table of the Elements, and such hydrocarbyl- or hydrocarbyl-substituted metalloid radicals further substituted with a Group 15 or 16 heteroatom containing moiety.
  • a radical selected from the group consisting of hydrogen, halogen, hydrocarbyl, halohydrocarbyl, Group 15 or 16 heteroatom-containing radicals, hydrocarbyl-substituted metalloid radicals wherein the metalloid is selected from Group 14 of the Periodic Table of the Elements, and such hydrocarbyl- or hydrocarbyl-substituted metalloid radicals further substituted with a Group 15 or 16 heteroatom containing moiety.
  • hydrocarbyl is C 1 -C 20 straight, branched and cyclic alkyl radicals, C 6 -C 20 aromatic radicals, C 7 -C 20 alkyl-substituted aromatic radicals, and C 7 -C 20 aryl-substituted alkyl radicals.
  • two or more such radicals may together form a fused ring system, including partially or fully hydrogenated fused ring systems, or they may form a metallocycle with the metal.
  • Suitable hydrocarbyl-substituted organometalloid radicals include mono-, di- and tri-substituted organometalloid radicals of Group 14 elements wherein each of the hydrocarbyl groups contains from 1 to 20 carbon atoms.
  • hydrocarbyl-substituted orgahometalloid radicals include trimethylsilyl, triethylsilyl, ethyldimethylsilyl, methyldiethyl-silyl, triphenylgermyl, and trimethylgermyl groups.
  • Group 15 or 16 hetero atom containing moieties include amine, phosphine, ether or thioether moieties or divalent derivatives thereof, e. g. amide, phosphide, ether or thioether groups bonded to the transition metal or Lanthanide metal, and bonded to the hydrocarbyl group or to the hydrocarbyl-substituted metalloid containing group.
  • Suitable anionic, delocalized ⁇ -bonded groups include but are not limited to cyclopentadienyl, indenyl, fluorenyl, tetrahydroindenyl, tetrahydrofluorenyl, octahydrofluorenyl, pentadienyl, dimethylcyclohexadienyl, dimethyldihydroanthracenyl, dimethylhexahydroanthracenyl, demethyldecahydroanthracenyl groups, and boratabenzene groups, as well as C 1-10 hydrocarbyl-substituted or C 1-10 hydrocarbyl-substituted silyl substituted derivatives thereof.
  • Preferred anionic delocalized ⁇ -bonded groups are cyclopentadienyl, tetramethylcyclopentadienyl, indenyl, 2,3-dimethylindenyl, fluorenyl, 2-methylindenyl, 2-methyl-4-phenylindenyl, tetrahydrofluorenyl, octahydrofluorenyl, tetrahydroindenyl, 2-methyl-s-indacenyl, 3-(N-pyrrolidinyl)indenyl, and cyclopenta(I)phenanthrenyl.
  • 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, 1995, 14, 1, 471-480. Preferred boratabenzenes correspond to the formula:
  • each R′′ is independently selected from the group consisting of hydrocarbyl, silyl, or germyl radicals, each said R′′ having up to 20 non-hydrogen atoms, and being optionally substituted with a group containing a Group 15 or 16 element.
  • hydrocarbyl, silyl, or germyl radicals each said R′′ having up to 20 non-hydrogen atoms, and being optionally substituted with a group containing a Group 15 or 16 element.
  • a preferred class of such Group 4 metal coordination complexes used according to the present invention correspond to the formula:
  • Cp is an anionic, delocalized, ⁇ -bonded group that is bound to M, containing up to 50 nonhydrogen atoms:
  • M is a metal of Group 4 of the Periodic Table of the Elements in the +2 or +4 formal oxidation state
  • X is a C 4-30 conjugated diene represented by the formula:
  • R 1 , R 2 , R 3 , and R 4 are each independently hydrogen, aromatic, substituted aromatic, fused aromatic, substituted fused aromatic, aliphatic, substituted aliphatic, heteroatom-containing aromatic, heteroatom-containing fused aromatic, or silyl radical;
  • Y is —O—, —S—, —NR—, or —PR—;
  • Z is SiR 2 , CR 2 , SiR 2 SiR 2 , CR 2 CR 2 , CR ⁇ CR, CR 2 SiR 2 , or GeR 2 , BR 2 , B(NR 2 ) 2 , BR 2 BR 2 , B(NR 2 ) 2 B(NR 2 ) 2 ,
  • R is in each occurrence independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinations thereof, said R having up to 20 non-hydrogen atoms, or adjacent R groups together form a divalent derivative (that is, a hydrocarbadiyl, siladiyl or germadiyl group) thereby forming a fused ring system.
  • a more preferred class of such Group 4 metal coordination complexes used according to the present invention correspond to the formula:
  • M is titanium or zirconium in the +2 or +4 formal oxidation state
  • X is a C 5-30 conjugated diene represented by the formula:
  • R 1 , R 2 , R 3 , and R 4 are each independently hydrogen, aromatic, substituted aromatic, fused aromatic, substituted fused aromatic, aliphatic, substituted aliphatic, heteroatom-containing aromatic, heteroatom-containing fused aromatic, or silyl radical;
  • Y is —O—, —S—, —NR*—, —PR*;
  • R and R* are in each occurrence is independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinations thereof, said R having up to 20 non-hydrogen atoms, or adjacent R groups together form a divalent derivative (that is, a hydrocarbadiyl, siladiyl or germadiyl group) thereby forming a fused ring system.
  • Illustrative Group 4 metal complexes that may be employed in the practice of the present invention include:
  • Suitable activating cocatalysts for use herein include ion forming compounds (including the use of such compounds under oxidizing conditions), especially the use of ammonium-, phosphonium-, oxonium-, carbonium, silylium-, sulfonium-, or ferrocenium-salts of compatible, noncoordinating anions, Lewis acids, such as C 1-30 hydrocarbyl substituted Group 13 compounds, especially tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron compounds and halogenated (including perhalogenated) derivatives thereof, having from 1 to 20 carbons in each hydrocarbyl or halogenated hydrocarbyl group, more especially perfluorinated tri(aryl)boron compounds, and most especially tris(pentafluorophenyl)borane, and combinations of the foregoing activating cocatalysts.
  • Lewis acids such as C 1-30 hydrocarbyl substituted Group 13 compounds, especially tri(hydrocar
  • Combinations of Lewis acids especially the combination of a trialkyl aluminum compound having from 1 to 4 carbons in each alkyl group and a halogenated tri(hydrocarbyl)boron compound having from 1 to 20 carbons in each hydrocarbyl group, especially tris(pentafluorophenyl)borane, further combinations of such Lewis acid mixtures with a polymeric or oligomeric alumoxane, and combinations of a single neutral Lewis acid, especially tris(pentafluorophenyl)borane with a polymeric or oligomeric alumoxane may also be used.
  • Suitable ionic compounds useful as cocatalysts in one embodiment of the present invention comprise a cation which is a Bronsted acid capable of donating a proton, and a compatible, noncoordinating anion, A ⁇ .
  • noncoordinating means an anion or substance which either does not coordinate to the Group 4 metal containing precursor complex and the catalytic derivative derived therefrom, or which is only weakly coordinated to such complexes thereby remaining sufficiently labile to be displaced by a Lewis bases such as olefin monomer.
  • a noncoordinating anion specifically refers to an anion which when functioning as a charge balancing anion in a cationic metal complex does not transfer an anionic substituent or fragment thereof to said cation thereby forming neutral complexes.
  • “Compatible anions” are anions which are not degraded to neutrality when the initially formed complex decomposes and are noninterfering with desired subsequent polymerization or other uses of the complex.
  • Preferred anions are those containing a coordination complex comprising one or more charge-bearing metal or metalloid atoms which anion is capable of balancing the charge of the active catalyst species (the metal cation) which may be formed when the two components are combined. Also, said anion should be sufficiently labile to be displaced by olefinic, diolefinic and acetylenically unsaturated compounds or other Lewis bases such as ethers or nitriles.
  • Suitable metals include, but are not limited to, aluminum, gold and platinum.
  • Suitable metalloids include, but are not limited to, boron, phosphorus, and silicon.
  • Compounds containing anions which comprise coordination complexes containing a single metal or metalloid atom are, of course, well known and many, particularly such compounds containing a single boron atom in the anion portion, are available commercially.
  • cocatalysts may be represented by the following general formula:
  • L* is a neutral Lewis base
  • A′ d ⁇ is a noncoordinating, compatible anion having a charge of d ⁇ .
  • d is an integer from 1 to 3.
  • A′ d ⁇ corresponds to the formula: [M*Q 4 ];
  • M* is boron or aluminum in the +3 formal oxidation state
  • Q independently each occurrence is selected from hydride, dialkylamido, halide, hydrocarbyl, halohydrocarbyl, halocarbyl, hydrocarbyloxide, hydrocarbyloxy substituted-hydrocarbyl, organometal-substituted hydrocarbyl, organometalloid substituted-hydrocarbyl, organometal-substituted hydocarbyloxy, halohydrocarbyloxy, halohydrocarbyloxy substituted hydrocarbyl, halocarbyl-substituted hydrocarbyl, and halo-substituted silylhydrocarbyl radicals (including perhalogenated hydrocarbyl-perhalogenated hydrocarbyloxy- and perhalogenated silylhydrocarbyl radicals), said Q having up to 20 carbons with the proviso that in not more than one occurrence is Q halide.
  • Suitable Q groups are disclosed in U.S. Pat. No. 5,296,433 and WO 98/27119, as well as elsewhere.
  • d is one, that is, the counter ion has a single negative charge and is A′ ⁇ .
  • Activating cocatalysts comprising boron which are particularly useful in the preparation of catalysts of this invention may be represented by the following general formula:
  • B is boron in a formal oxidation state of 3;
  • Q is a hydrocarbyl-, hydrocarbyloxy-, orgaonmetal-substituted hydrocarbyloxy, fluorinated hydrocarbyl-, fluorinated hydrocarbyloxy-, or fluorinated silylhydrocarbyl-group of up to 20 nonhydrogen atoms, with the proviso that in not more than one occasion is Q hydrocarbyl.
  • Q is each occurrence a fluorinated aryl group, or dialkylaluminumoxyphenyl group, especially, a pentafluorophenyl group or diethylaluminumoxyphenyl group.
  • boron compounds which may be used as an activating cocatalyst in the preparation of the improved catalysts of this invention are tri-substituted ammonium salts such as:
  • Dialkyl ammonium salts such as:
  • Tri-substituted phosphonium salts such as:
  • armeenium salt cocatalysts are methyldi(octadecyl)ammonium tetrakis(pentafluorophenyl)borate and methyldi(tetradecyl)ammonium tetrakis(pentafluorophenyl)borate, or mixtures including the same
  • Such mixtures include protonated ammonium cations derived from amines comprising two C 14 , C 16 or C 18 alkyl groups and one methyl group.
  • Such amines are referred to herein as armeens and the cationic derivatives thereof are referred to as armeenium cations. They are available from Witco Corp., under the trade name KemamineTM T9701, and from Akzo-Nobel under the trade name ArmeenTMM2HT.
  • Another suitable ammonium salt, especially for use in heterogeneous catalyst compositions is formed upon reaction of a organometal or organometalloid compound, especially a tri(C 1-6 alkyl)aluminum compound with an ammonium salt of a hydroxyaryltris(fluoroaryl)borate compound.
  • the resulting compound is an organometaloxyaryltris(fluoroaryl)borate compound which is generally insoluble in aliphatic liquids.
  • such compounds are advantageously precipitated on support materials, such as silica, alumina or trialkylaluminum passivated silica, to form a supported cocatalyst mixture.
  • Suitable compounds include the reaction product of a tri(C 1-6 alkyl)aluminum compound with the ammonium salt of hydroxyaryltris(fluoroaryl)borate.
  • exemplary fluoroaryl groups include perfluorophenyl, perfluoronaphthyl, and perfluorobiphenyl.
  • Particularly preferred hydroxyaryltris(fluoroaryl)-borates include the ammonium salts, especially the forgoing armeenium salts of:
  • An especially preferred ammonium compound is methyldi(tetradecyl)ammonium (4-diethylaluminumoxy-1-phenyl)tris(pentafluorophenyl)borate, methyldi(hexadecyl)ammonium (4-diethylaluminumoxy-1-phenyl)tris(pentafluorophenyl)borate, methyldi(octadecyl)ammonium (4-diethylaluminumoxy-1-phenyl)tris(pentafluorophenyl)borate, and mixtures thereof.
  • the foregoing complexes are disclosed in WO96/28480, which is equivalent to U.S. Ser. No. 08/610,647, filed Mar. 4, 1996, and in U.S. Ser. No. 08/768,518, filed Dec. 18, 1996.
  • Another suitable activating cocatalyst comprises a salt of a cationic oxidizing agent and a noncoordinating, compatible anion represented by the formula:
  • Ox e+ is a cationic oxidizing agent having a charge of e+
  • e is an integer from 1 to 3;
  • A′ d ⁇ and d are as previously defined.
  • Examples of cationic oxidizing agents include: ferrocenium, hydrocarbyl-substituted ferrocenium, Ag + or Pb +2 .
  • Preferred embodiments of A′ d ⁇ are those anions previously defined with respect to the Bronsted acid containing activating cocatalysts, especially tetrakis(pentafluorophenyl)borate.
  • Another suitable activating cocatalyst comprises a compound which is a salt of a carbenium ion and a noncoordinating, compatible anion represented by the formula:
  • ⁇ + is a C 1-20 carbenium ion
  • A′ ⁇ is a noncoordinating, compatible anion having a charge of ⁇ 1.
  • a preferred carbenium ion is the trityl cation, that is triphenylmethylium.
  • a further suitable activating cocatalyst comprises a compound which is a salt of a silylium ion and a noncoordinating, compatible anion represented by the formula:
  • R is C 1-10 hydrocarbyl
  • X′ is a Lewis base
  • n 0, 1 or 2
  • A′ ⁇ is as previously defined.
  • Preferred silylium salt activating cocatalysts are trimethylsilylium tetrakispentafluorophenylborate, triethylsilylium tetrakispentafluorophenylborate and ether substituted adducts thereof.
  • Silylium salts have been previously generically disclosed in J. Chem Soc. Chem. Comm., 1993, 383-384, as well as Lambert, J. B., et al., Organometallics, 1994, 13, 2430-2443.
  • the use of the above silylium salts as activating cocatalysts for addition polymerization catalysts is claimed in U.S. Pat. No. 5,625,087.
  • the cocatalyst will comprise a compound corresponding to the formula: (A +a ) b (EJ j ) ⁇ c d,
  • A is a cation of charge +a
  • E is an anion group of from 1 to 30 atoms, not counting hydrogen atoms, further containing two or more Lewis base sites;
  • J independently each occurrence is a Lewis acid coordinated to at least one Lewis base site of E, and optionally two of more such J groups may be joined together in a moiety having multiple Lewis acidic functionality,
  • j is a number from 2 to 12 and
  • a, b, c, and d are integers from 1 to 3, with the proviso that a ⁇ b is equal to c ⁇ d.
  • Such compounds are disclosed and claimed in U.S. Ser. No. 09/251664, filed Feb. 17, 1999.
  • a + is as previously defined, and preferably is a trihydrocarbyl ammonium cation, containing one or two C 10-40 alkyl groups, especially, methyldioctadecylammonium cation,
  • R′ is in each occurrence is independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinations thereof, each said R′ having up to 30 non-hydrogen atoms (especially methyl or a C 10 or higher hydrocarbyl group), and
  • L is a trisfluoroarylboron or trisfluoroarylaluminum compound containing three C 6-20 fluoroaryl-groups, especially pentafluorophenyl groups.
  • the molar ratio of catalyst/cocatalyst employed preferably ranges from 1:10 to 10:1, more preferably from 1:5 to 5:1, most preferably from 1:1.5 to 1.5:1.
  • the catalyst and activating cocatalyst are present on the support in an amount of from 5 to 200, more preferably from 10 to 75 micromoles per gram of support.
  • Preferred supports for use in the present invention include highly porous silicas, aluminas, aluminosilicates, and mixtures thereof.
  • the most preferred support material is silica.
  • the support material may be in granular, agglomerated, pelletized, 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 designations SD 3216.30, Davison Syloid 245, Davison 948 and Davison 952, and from Crossfield under the designation ES70, and from Degussa AG under the designation Aerosil 812; and aluminas available from Akzo Chemicals Inc. under the designation Ketzen Grade B.
  • Supports suitable for the present invention preferably have a surface area as determined by nitrogen porosimetry using the B.E.T. method from 10 to 1000 m 2 /g, and preferably from 100 to 600 m 2 /g.
  • the pore volume of the support, as determined by nitrogen adsorption, advantageously is from 0.1 to 3 cm 3 /g, preferably from 0.2 to 2 cm 3 /g.
  • the average particle size depends upon the process employed, but typically is from 0.5 to 500 ⁇ m, preferably from 1 to 100 ⁇ m.
  • Both silica and alumina are known to inherently possess small quantities of hydroxyl functionality.
  • these materials are preferably subjected to a heat treatment or a combination thereof chemical treatment to reduce the hydroxyl content thereof.
  • Typical heat treatments are carried out at a temperature from 30° C. to 1000° C. (preferably 250° C. to 800° C. for 4 hours or greater) for a duration of 10 minutes to 50 hours in an inert atmosphere or air or under reduced pressure, that is, at a pressure of less than 200 Torr.
  • preferred temperatures are from 100 to 800° C.
  • Residual hydroxyl groups are then removed via chemical treatment.
  • Typical chemical treatments include contacting with Lewis acid alkylating agents such as trihydrocarbyl aluminum compounds, trihydrocarbylchlorosilane compounds, trihydrocarbylalkoxysilane compounds or similar agents.
  • the support may be functionalized with a silane or chlorosilane functionalizing agent to attach thereto pendant silane —(Si—R) ⁇ , or chlorosilane —(Si—CI) ⁇ functionality, wherein R is a C 1-10 to hydrocarbyl group.
  • Suitable functionalizing 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 functionalizing agents include phenylsilane, hexamethyldisilazane diphenylsilane, methylphenylsilane, dimethylsilane, diethylsilane, dichlorosilane, and dichlorodimethylsilane. Techniques for forming such functionalized silica or alumina compounds were previously disclosed in U.S. Pat. Nos. 3,687,920 and 3,879,368.
  • the functionalizing agent may be an aluminum component selected from an alumoxane or an aluminum compound of the formula AIR 1 x , R 2 y , wherein:
  • R 1 independently each occurrence is hydride or R′′
  • R 2 is hydride, R′′ or OR′′
  • R′′ is in each occurrence is independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, said R′′ having up to 20 non-hydrogen atoms,
  • x′ is 2 or 3
  • y′ is 0 or 1
  • R 1 and R 2 groups examples include methyl, methoxy, ethyl, ethoxy, propyl (all isomers), propoxy (all isomers), butyl (all isomers), butoxy (all isomers), phenyl, phenoxy, benzyl, and benzyloxy.
  • the aluminum component is selected from the group consisting of tri(C 1-4 hydrocarbyl)aluminum compounds. Most preferred aluminum components are trimethylaluminum, triethylaluminum, tri-isobutylaluminum, and mixtures thereof.
  • Such treatment typically occurs by:
  • Suitable support materials also referred to as carriers or carrier materials, used in the present invention include those support materials which are typically used in the art of supported catalysts, and more in particular the art of supported olefin addition polymerization supported catalysts.
  • Examples include porous resinous materials, for example, polyolefins such as polyethylenes and polypropylenes or copolymers of styrene-divinylbenzene, and solid inorganic oxides including oxides of Group 2, 3, 4, 13, or 14 metals, such as silica, alumina, magnesium oxide, titanium oxide, thorium oxide, as well as mixed oxides of silica.
  • Suitable mixed oxides of silica include those of silica and one or more Group 2 or 13 metal oxides, such as silica-magnesia or silica-alumina mixed oxides.
  • Silica, alumina, and mixed oxides of silica and one or more Group 2 or 13 metal oxides are preferred support materials. Preferred examples of such mixed oxides are the silica-aluminas.
  • the most preferred support material is silica.
  • the shape of the silica particles is not critical and the silica may be in granular, spherical, agglomerated, fumed or other form.
  • Support materials suitable for the present invention preferably have a surface area as determined by nitrogen porosimetry using the B.E.T. method from 10 to 1000 m 2 /g, and preferably from 100 to 600 m 2 /g.
  • the pore volume of the support, as determined by nitrogen adsorption, is typically up to 5 cm 3 /g, advantageously between 0.1 and 3 cm 3 /g, preferably from 0.2 to 2 cm 3 /g.
  • the average particle size is not critical but typically is from 0.5 to 500 ⁇ m, preferably from 1 to 200 ⁇ m, more preferably to 100 ⁇ m.
  • Preferred supports for use in the present invention include highly porous silicas, aluminas, aluminosilicates, and mixtures thereof.
  • the most preferred support material is silica.
  • the support material may be in granular, agglomerated, pelletized, 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 designations SD 3216.30, Davison SyloidTM245, Davison 948 and Davison 952, and from Crosfield under the designation ES70, and from Degussa AG under the designation AerosilTM812; and aluminas available from Akzo Chemicals Inc. under the designation KetzenTM Grade B.
  • Both silica and alumina are known to inherently possess small quantities of hydroxyl functionality.
  • these materials are preferably subjected to a heat treatment or a combination thereof chemical treatment to reduce the hydroxyl content thereof.
  • Typical heat treatments are carried out at a temperature from 30° C. to 1000° C. (preferably 250° C. to 800° C. for 5 hours or greater) for a duration of 10 minutes to 50 hours in an inert atmosphere or air or under reduced pressure, that is, at a pressure of less than 200 Torr.
  • preferred temperatures are from 100 to 800° C.
  • Residual hydroxyl groups are then removed via chemical treatment.
  • Typical chemical treatments include contacting with Lewis acid alkylating agents such as trihydrocarbyl aluminum compounds, trihydrocarbylchlorosilane compounds, trihydrocarbylalkoxysilane compounds or similar agents.
  • the support may be functionalized with a silane or chlorosilane functionalizing agent to attach thereto pendant silane —(Si—R) ⁇ , or chlorosilane —(Si—Cl) ⁇ functionality, wherein R is a C 1-10 hydrocarbyl group.
  • Suitable functionalizing 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 functionalizing agents include phenylsilane, hexamethyldisilazane diphenylsilane, methylphenylsilane, dimethylsilane, diethylsilane, dichlorosilane, and dichlorodimethylsilane. Techniques for forming such functionalized silica or alumina compounds were previously disclosed in U.S. Pat. Nos. 3,687,920 and 3,879,368, the teachings of which are herein.
  • the metal complex, cocatalyst, and catalyst support are slurried together in a compatible solvent, typically utilizing an amount of solvent which is greater than the pore volume of the support.
  • the supported catalyst composition is subsequently dried while applying heat or a combination thereof vacuum to render the supported catalyst composition substantially free of solvent.
  • a sequential double impregnation technique in employed.
  • the support is heated to remove water and reacted with a suitable functionalizing agent to form a support precursor.
  • the support precursor is sequentially contacted by a first solution of either the metal complex or the cocatalyst, and thereafter by a second solution of the other of the metal complex or the cocatalyst.
  • the contacting solution will be provided in an amount such that 100 percent of the pore volume of the support precursor is at no time exceeded.
  • the support precursor may be dried to remove compatible solvent after contacting with the first solution. This feature, however, is not required, provided the solid remains as a dry, free-flowing powder.
  • the support is heated to remove water and reacted with a suitable functionalizing agent to form a support precursor.
  • the support precursor is slurried in a first solution of the metal complex or the cocatalyst to form a supported procatalyst.
  • Sufficient compatible solvent is removed from the supported procatalyst to result in a recovered supported procatalyst that is free-flowing, that is, wherein the amount of compatible solvent is less than 100 percent of the pore volume of the support precursor.
  • the recovered supported procatalyst is contacted with a second solution of the other of the metal complex or cocatalyst, whereupon the second solution is provided in an amount less than 100 percent of the pore volume of the support precursor, to form the supported catalyst composition.
  • the amount of the second solution is insufficient to render the supported catalyst composition not free-flowing, an additional solvent removal step is unnecessary.
  • compatible solvent may be more fully removed by application of heat, reduced pressure, or a combination thereof.
  • the metal complex will be applied in the first solution, and the cocatalyst will be applied in the second solution, particularly when the cocatalyst is easily degraded by the application of heat or a combination thereof vacuum during drying.
  • the catalysts compositions of the invention prior to exposure to polymerization conditions are believed to remain primarily in unaltered chemical form, that is, the metal complex and cocatalyst remain relatively unaltered and catalytically inactive until exposed to polymerization conditions.
  • the catalyst composition becomes more active.
  • catalysts with lower initial reaction exotherms and increasing rates of polymerization may be prepared, which may lead to improved performance in the polymerization reactor and improved polymer morphology.
  • the catalysts may be used to polymerize ethylenically or a combination thereof acetylenically unsaturated monomers having from 2 to 100,000 carbon atoms either alone or in combination.
  • Preferred monomers include the C 2-20 ⁇ -olefins especially ethylene, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-octene, 1-decene, long chain macromolecular ⁇ -olefins, and mixtures thereof.
  • styrene C 1-4 alkyl substituted styrene, tetrafluoro-ethylene, vinylbenzocyclobutane, ethylidenenorbomene, 1,4-hexadiene, 1,7-octadiene, vinylcyclohexane, 4-vinylcyclohexene, divinylbenzene, and mixtures thereof with ethylene.
  • Long chain macromolecular a-olefins are vinyl terminated polymeric remnants formed in situ during continuous solution polymerization reactions.
  • ⁇ -olefin polymers prepared by use of the catalyst compositions of the present invention have reverse molecular molecular architecture, by which is meant that a copolymer of two or more olefins contains increased content of the higher molecular weight comonomer in the higher molecular weight fractions thereof.
  • the polymerization may be accomplished at conditions well known in the prior art for Ziegler-Natta or Kaminsky-Sinn type polymerization reactions, such as temperatures from 0-250° C. and pressures from atmospheric to 1000 atmospheres (0.1 to 100 MPa.
  • feed streams shall be appropriately dried and deoxygenated to remove impurities; temperature controls shall be in place to minimize reaction exotherm and prevent runaway reactions; suitable scavengers will be employed as needed, for instance, alkyl-aluminum treated silica, potassium hydride, etc.
  • Suitable gas phase reactions may utilize condensation of the monomer or monomers employed in the reaction, or of an inert diluent to remove heat from the reactor.
  • the support is preferably employed in an amount to provide a weight ratio of catalyst (based on metal):support from 1:100,000 to 1:10, more preferably from 1:50,000 to 1:20, and most preferably from 1:10,000 to 1:30.
  • the molar ratio of catalyst:polymerizable compounds employed is from 10 ⁇ 12 :1 to 10 ⁇ 1 :1, more preferably from 10 ⁇ 12 :1 to 10 ⁇ 5 :1.
  • the catalysts may also be utilized in combination with at least one additional homogeneous or heterogeneous polymerization catalyst in the same or in separate reactors connected in series or in parallel to prepare polymer blends having desirable properties.
  • An example of such a process is disclosed in WO 94/00500, equivalent to U.S. Ser. No. 07/904,770, as well as U.S. Ser. No. 08/10958, filed Jan. 29, 1993, the teachings of which are hereby herein.
  • M is titanium or zirconium in the +2 or +4 formal oxidation state
  • X is diphenylbutadiene, or 1,6-diphenyl-2,4-hexadiene
  • Y is —NR—
  • Z is SiR 2 .
  • R is in each occurrence is independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinations thereof, said R having up to 20 non-hydrogen atoms, or adjacent R groups together form a divalent derivative (that is, a hydrocarbadiyl, siladiyl or germadiyl group) thereby forming a fused ring composition.
  • cocatalysts formed as the reaction of a organometal compound, especially a tri(C 1-6 alkyl)aluminum compound with an ammonium salt of a hydroxyaryltris(fluoroaryl)borate compound, have been found to be preferred for use in the practice of the claimed invention.
  • Such cocatalysts may be advantageously capped to form organometaloxyaryltris(fluoroaryl)borate compounds which renders them insoluble in hexane, and facilitates their precipitation onto the support, typically silica, alumina or trialkylaluminum passivated silica.
  • An especially preferred cocatalyst for use in the practice of the claimed invention include the reaction product of a tri(C 1-6 alkyl)aluminum compound with the ammonium salt of diethylaluminumoxyaryltris(perfloroaryl)borate.
  • Bis(hydrogenated tallow alkyl)methyl ammonium tris(pentafluorophenyl)(4-hydroxyphenyl)borate was prepared as described in PCT98/27119.
  • ISOPAR®E hydrocarbon mixture was obtained from Exxon chemical company. All other solvents were purchased from Aldrich Chemical Company as anhydrous reagents and were further purified by a nitrogen purge and by passing them down a 12 inch column chunk alumina which had been heat treated overnight at 250° C. All other reagents were purchased from Aldrich Chemical Company and used without further purification.
  • a 200 g sample of Davison 948 silica (available from Grace-Davison) was calcined for 4 hours at 250° C. in air, then transferred to a nitrogen-filled glove box.
  • a 15 g sample of the silica was slurried in 90 mL hexane, and 30 mL of a 1.0 M solution of triethylaluminum in hexanes was added over several minutes. The addition rate was slow enough to prevent solvent reflux.
  • the slurry was agitated on a mechanical shaker for 1 hour. At this time, the solids were collected on a fritted funnel, washed three times with 50 mL portions of hexanes, and dried in vacuo.
  • the filtrate was concentrated to yield a yellow solid (1.2 g, 45 percent) which was an ⁇ 5:1 mixture of the trans,trans: cis-trans isomers.
  • the trans,trans isomer was selectively recrystallized from toluene (400 mg).
  • DIBAL-H diisobutylaluminum
  • a slurry of TEA-treated silica (prepared as described above, 2.00 g) in 5 mL of toluene was treated with a mixture of armeenium (p-hydroxyphenyl)tris(pentafluorophenyl)borate (2.0 mL. 0.040 M, 80 mmol) and TEA (0.88 mL, 0.10 M, 88 mmol).
  • TEA-treated silica prepared as described above was added a mixture of AM2HT (1.2 mL. of a 9.95 wt percent solution diluted to 3 mL) and TEA (0.05 mL of a 1.9 M solution in toluene). The mixture was vigorously agitated to a free flowing powder, and the solvent was removed in vacuo. Next, (t-butylamido)(dimethyl)(tetramethylcyclopentadienyl)silane titanium 1,4-dibenzylbutadiene (3.80 mL of a 0.023 M solution in toluene) was added. The mixture was agitated vigorously to a free flowing powder and then the volatiles were removed in vacuo.
  • a 2.5-L stirred, fixed bed autoclave was charged with 200 g dry NaCl containing 0.67 g TEA/silica, and stirring was begun at 300 rpm.
  • the reactor was pressurized to 7 bar ethylene and heated to 70° C.
  • 1-hexene was introduced to a level of 8000 ppm as measured by mass 84 on a mass spectrometer.
  • 0.1 g catalyst was mixed with an additional 0.5 g scavenger. The combined catalyst and scavenger were subsequently injected into the reactor. Ethylene pressure was maintained on a feed as demand, and hexene was fed as a liquid to the reactor to maintain the ppm concentration.
  • catalyst systems 3A, 2C, and 2D each exhibited a K, of less than 1.6.
  • each of these catalyst compositions exhibited a less decaying profile than that of comparative catalyst compositions 3B and 1C.

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