Passivated supports: catalyst, process, product and film
AssigneeNOVA Chemicals (International) S.A.
InventorsDarryl J Morrison, Patrick Lam
Life of this patent
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Abstract
Ethylene copolymers made in the gas phase using a phosphinimine based single site catalyst supported on a passivated inorganic oxide support. The ethylene copolymers have a relatively narrow molecular weight distribution and good rheological parameters.
Claims19
An olefin polymerization process to produce an ethylene copolymer, the process comprising contacting ethylene and at least one alpha olefin having from 3-8 carbon atoms with a polymerization catalyst in a gas phase reactor;
- wherein the ethylene copolymer has a density of from 0.916 g/cm3 to 0.936 g/cm3, a melt index (I2) of from 0.1 g/10 min to 2.0 g/10 min, a melt flow ratio (I21/I2) of greater than 22 but less than 42, a molecular weight distribution (Mw/Mn) of from 2.3 to 5.0, a reverse comonomer distribution profile as determined by GPC-FTIR, and a composition distribution breadth index CDBI50 of from 45 wt % to 80 wt % as determined by TREF;
- the polymerization catalyst comprises a phosphinimine catalyst, a passivated support and a co-catalyst;
- and the passivated support comprises silica which has been treated with i) an organoaluminum compound and ii) magnesium chloride;
- wherein the magnesium chloride is generated by addition of a diorganomagnesium compound and a source of chloride to the organoaluminum treated silica, provided that the source of chloride is not a transition metal chloride.
An olefin polymerization process to produce an ethylene copolymer, the process comprising contacting ethylene and at least one alpha olefin having from 3-8 carbon atoms with a polymerization catalyst in a single gas phase reactor;
- the ethylene copolymer having a density of from 0.916 g/cm3 to 0.936 g/cm3, and a melt flow ratio (I21/I2) of greater than 22 but less than 42;
- wherein the polymerization catalyst comprises a phosphinimine catalyst, a passivated support, and a co-catalyst;
- and the passivated support comprises silica which has been treated with i) an organoaluminum compound and ii) magnesium chloride;
- wherein the magnesium chloride is generated by addition of a diorganomagnesium compound and a source of chloride to the organoaluminum treated silica, provided that the source of chloride is not a transition metal chloride;
- and wherein the phosphinimine catalyst has the formula:
- (1-R¥-Indenyl)((t-Bu)3P═N)TiX2, where R¥ is an alkyl group, an aryl group or a benzyl group and wherein each of the alkyl group, the aryl group, and the benzyl group is unsubstituted or is substituted by at least one fluoride atom;
- and X is an activatable ligand.
An ethylene copolymer having a density of from 0.916 g/cm3 to 0.936 g/cm3, a melt index (I2) of from 0.1 g/10 min to 2.0 g/10 min, a melt flow ratio (I21/I2) of greater than 22 but less than 40, a molecular weight distribution (Mw/Mn) of from 2.5 to 4.5, a z-average molecular weight distribution (Mz/Mw) of less than 3.0, a reverse comonomer distribution profile as determined by GPC-FTIR, and a composition distribution breadth index CDBI50 of from 50 wt % to 80 wt % as determined by TREF, and a bimodal TREF profile;
- wherein the ethylene copolymer is made in a single gas phase reactor using a polymerization catalyst comprising:
- a phosphinimine catalyst, a passivated support and a co-catalyst;
- wherein the passivated support comprises silica which has been treated with i) an organoaluminum compound and ii) magnesium chloride;
- and wherein the magnesium chloride is generated by addition of a diorganomagnesium compound and a source of chloride to the organoaluminum treated silica, provided that the source of chloride is not a transition metal chloride.
A film layer comprising an ethylene copolymer having a density of from 0.916 g/cm3 to 0.936 g/cm3, a melt index (I2) of from 0.1 g/10 min to 2.0 g/10 min, a melt flow ratio (I21/I2) of greater than 22 but less than 40, a molecular weight distribution (Mw/Mn) of from 2.5 to 4.5, a z-average molecular weight distribution (Mz/Mw) of less than 3.0, a reverse comonomer distribution profile as determined by GPC-FTIR, and a composition distribution breadth index CDBI50 of from 50 wt % to 80 wt % as determined by TREF, and a bimodal TREF profile;
- wherein the ethylene copolymer is made in a single gas phase reactor using a polymerization catalyst comprising:
- a phosphinimine catalyst, a passivated support and a co-catalyst;
- wherein the passivated support comprises silica which has been treated with i) an organoaluminum compound and ii) magnesium chloride;
- and wherein the magnesium chloride is generated by addition of a diorganomagnesium compound and a source of chloride to the organoaluminum treated silica, provided that the source of chloride is not a transition metal chloride.
Dependencies are inferred from the claim text.