Single Site Catalyst Supportation

A single site catalyst system comprising:

• (a) a single site catalyst precursor compound;
• (b) an activator;
• (c) a support having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m2/g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å);
• (d) a polypropylene matrix having a porosity of at least 15%, and a volume average median pore diameter of less than 165 μm, as determined by mercury intrusion porosimetry;
• and
• (e) active catalyst sites distributed in the matrix.

A process, comprising:

• (a) contacting a single site catalyst precursor compound, an activator and a support, the support having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m2/g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å), to form a supported catalyst system;
• (b) contacting the supported catalyst system and propylene monomer under polymerization conditions to form a matrix of porous propylene polymer comprising at least 50 mol % propylene and a mean pore diameter less than 165 μm as determined by mercury intrusion porosimetry;
• and
• (c) dispersing active catalyst system sites within the matrix.