Catalyst systems and processes for producing polyethylene using the same
AssigneeDow Global Technologies LLC
InventorsRhett A. Baillie, Hien Q. Do, David M. Pearson, Johnathan E. Delorbe, Andrew M. Camelio, Philip P. Fontaine
Life of this patent
Estimating the term…
Abstract
Embodiments of the present application are directed to procatalysts, and catalyst systems including procatalysts, including a metal-ligand complex having the structure of formula (I):
Claims17
A process for producing an ethylene-based copolymer having a reverse comonomer distribution, the process comprising polymerizing ethylene and one or more (C3-C12)α-olefin comonomers in the presence a catalyst system in a single gas-phase polymerization reactor at a reactor temperature of 60° C. to less than or equal to 150° C. and a molar feed ratio of less than or equal to 0.020 of the one or more (C3-C12)α-olefin comonomers to the ethylene, wherein:
- the catalyst system comprises one or more support materials and an activated metal-ligand complex having a structure according to formula (Ia):
- wherein:
- A− is an anion;
- M is titanium, zirconium, or hafnium;
- n is 1, 2, or 3;
- each X is a monodentate ligand independently chosen from unsaturated (C2-C50)hydrocarbon, unsaturated (C2-C50)heterohydrocarbon, (C1-C50)hydrocarbyl, (C1-C50)heterohydrocarbyl, (C6-C50)aryl, (C4-C50)heteroaryl, halogen, —N(RN)2, and —N(RN)CORC;
- each Z is independently chosen from —O—, —S—, (C6-C50)aryl, (C4-C50)heteroaryl, N(C1-C40)hydrocarbyl, and P(C1-C40)hydrocarbyl;
- R1 and R16 are independently chosen from (C6-C50)aryl, (C4-C50)heteroaryl, (C1-C40)alkyl, (C3-C40)heteroalkyl, radicals having formula (II), radicals having formula (III), and radicals having formula (IV):
- wherein R31-35, R41-48, and R51-59 are independently chosen from —H, (C1-C50)hydrocarbyl, (C1-C50)heterohydrocarbyl, —Si(RC)3, —Ge(RC)3, —P(RP)2, —N(RN)2, —ORC, —SRC, —NO2, —CN, —CF3, RCS(O)—, RCS(O)2—, (RC)2C═N—, RCC(O)O—, RCOC(O)—, RCC(O)N(RN)—, (RC)2NC(O)—, or halogen;
- R2, R3, R4, R5, R6, R7, R8, R9, R10, R11, R12, R13, R14, and R15 are independently chosen from —H, (C1-C50)hydrocarbyl, (C1-C50)heterohydrocarbyl, —Si(RC)3, —Ge(RC)3, —P(RP)2, —N(RN)2, —ORC, —SRC, —NO2, —CN, —CF3, RCS(O)—, RCS(O)2—, (RC)2C═N—, RCC(O)O—, RCOC(O)—, RCC(O)N(R)—, (RC)2NC(O)—, and halogen;
- R17 and R18 are independently chosen from —(CRC2)m—, wherein subscript m is from 1 to 10;
- R19 and R20 are independently chosen from linear or branched (C1-C20)alkyl;
- and
- each RC, RP, and RN are independently chosen from —H, (C1-C50)hydrocarbyl, and (C1-C50)heterohydrocarbyl;
- and
- the ethylene-based copolymer has a unimodal molecular weight distribution as determined by gel permeation chromatography (GPC) and a molecular weight comonomer distribution index of greater than 0 as determined by determined by rapid Fourier Transform-Infrared (FT-IR) spectroscopy on dissolved copolymer during the gel permeation chromatography (GPC) measurement.
A process for producing an ethylene-based copolymer having a reverse comonomer distribution, the process comprising polymerizing ethylene and one or more (C3-C12)α-olefin comonomers in the presence a catalyst system in a single gas-phase polymerization reactor at a reactor temperature of less than or equal to 150° C. and a molar feed ratio of less than or equal to 0.020 of the one or more (C3-C12)α-olefin comonomers to the ethylene, wherein:
- the catalyst system comprises an activated metal-ligand complex having a Group IV metal center and at least one dianionic heterohydrocarbyl ligand and one or more monoanionic hydrocarbyl ligand provided that the ligand is not cyclopentadienyl;
- wherein the catalyst system does not contain a support material;
- and
- the ethylene-based copolymer has a unimodal molecular weight distribution and a molecular weight comonomer distribution index of greater than 0.
Dependencies are inferred from the claim text.