Catalyst systems and processes for producing polyethylene using the same
AssigneeDow Global Technologies LLC
InventorsRhett A. Baillie, Johnathan E. Delorbe, Andrew M. Camelio, Hien Q Do, Philip P. Fontaine, David M. Pearson, Mari S. Rosen, Brad C. Bailey
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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):
Claims20
A process for producing polyethylene, the process comprising contacting ethylene and, optionally, one or more (C3-C12)α-olefin comonomers with a catalyst system in a gas-phase polymerization reactor at a reactor temperature of 70° C. to less than or equal to 150° C. with an ethylene partial pressure greater than or equal to 150 psi, and a molar feed ratio of less than or equal to 0.030 of one or more (C3-C12)α-olefin comonomers to ethylene using the catalyst system comprising a metal-ligand complex disposed on one or more support materials, wherein the metal-ligand complex has 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 selected from the group consisting of (C1-C50)hydrocarbyl, (C1-C50)heterohydrocarbyl, (C6-C50)aryl, (C2-C50)heteroaryl, and halogen;
- R1 and R8 are independently selected from the group consisting of radicals having formula (II), and radicals having formula (III):
- wherein R9-13, and R14-21 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, and halogen;
- R2, R3, R4, R5, R6, and R7 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, and halogen;
- and
- an amount of ethylene consumed during the first 5 minutes upon injection of the catalyst system into the gas-phase polymerization reactor is less than 25% of the total ethylene consumed for the time of the entirety of the average residence time, tR, upon initial addition of the catalyst system, wherein the time at which 25% of the total ethylene uptake (t25%) is calculated by the equation according to formula (IV):
- ∑
- t
- =
- 0
- t
- 25
-
- %
-
- C
-
- 2
-
- (
- t
- )
- ∑
- t
- =
- 0
- t
- R
-
- C
-
- 2
-
- (
- t
- )
- =
- 0.25
- ,
- and
-
- t
- 25
-
- %
- >
- 5
-
- min
- .
- (
- IV
- )
A process for producing polyethylene, the process comprising contacting ethylene and, optionally, one or more (C3-C12)α-olefin comonomers with a catalyst system in a gas-phase polymerization reactor at a reactor temperature of 70° C. to less than or equal to 150° C. with an ethylene partial pressure of 50 psi to 150 psi, and a molar feed ratio of less than or equal to 0.030 of one or more (C3-C12)α-olefin comonomers to ethylene using the catalyst system comprising a metal-ligand complex disposed on one or more support materials, wherein the metal-ligand complex has 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 selected from a group consisting of (C1-C50)hydrocarbyl, (C1-C50)heterohydrocarbyl, (C6-C50)aryl, (C4-C50)heteroaryl, and halogen;
- R1 and R8 are independently selected from a group consisting of radicals having formula (II), and radicals having formula (III):
- wherein R9-13, and R14-21 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, and halogen;
- R2, R3, R4, R5, R6, and R7 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, and halogen;
- and
- an amount of ethylene consumed during the first 25 minutes upon injection of the catalyst system into the gas-phase polymerization reactor is less than 50% of the total ethylene consumed for the time of the entirety of the average residence time, tR, upon initial addition of the catalyst system, wherein the time at which 25% of the total ethylene uptake (t25%) is calculated by the equation according to formula (IV):
- ∑
- t
- =
- 0
- t
- 2
-
- 5
-
- %
-
- C
-
- 2
-
- (
- t
- )
- ∑
- t
- =
- 0
- t
- R
-
- C
-
- 2
-
- (
- t
- )
- =
- 0.25
- ,
- and
-
- t
- 2
-
- 5
-
- %
- >
- 5
-
- min
- .
- (
- IV
- )
Dependencies are inferred from the claim text.