Catalyst composition and methods for its preparation and use in a polymerization process
AssigneeUnivation Technologies, LLC
InventorsAgapios K. Agapiou, Chi-I Kuo, David M. Glowczwski, Steve K. Ackerman
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Abstract
The present invention relates to a catalyst composition and a method for making the catalyst composition of a polymerization catalyst and a carboxylate metal salt. The invention is also directed to the use of the catalyst composition in the polymerization of olefin(s). In particular, the polymerization catalyst system is supported on a carrier.
Claims40
A continuous process for polymerizing olefin monomer(s) in a reactor under polymerization conditions, the process comprising the steps of:
- (a) introducing olefin monomer(s) to the reactor;
- (b) (i) introducing a polymerization catalyst;
- and (ii) an additive which is a 13 metal carboxylate salt;
- and
- (c) withdrawing a polymer product from the reactor.
A continuous gas phase process for polymerizing monomer(s) in a reactor, said process comprising the steps of:
- (a) introducing a recycle stream into the reactor, the recycle stream comprising one or more monomer(s);
- (b) introducing a polymerization catalyst, and a 13 metal carboxylate salt into the reactor;
- (c) withdrawing the recycle stream from the reactor;
- (d) cooling the recycle stream;
- (e) reintroducing the recycle stream into the reactor;
- (f) introducing into the reactor additional monomer(s) to replace the monomer(s) polymerized;
- and
- (g) withdrawing a polymer product from the reactor.
A continuous gas phase polymerization process for polymerizing ethylene and one or more alpha-olefins having 4 or more carbon atoms comprising polymerizing in the presence of a polymerization catalyst and an additive which is a 13 metal carboxylate salt, at a pressure in the range of from about 200 psig (1379 kPa) to about 400 psig (2759 kPa), a polymerization temperature in the range of from about 70° C. to about 110° C., at a production rate of greater than 10,000 pounds (4540 Kg) of a polymer product per hour, and at a polymerization catalyst productivity of greater than 1500 grams of the polymer product per gram of the polymerization catalyst.
A polymerization process for producing a first ethylene based polymer product having a density greater than 0.87 g/cc and a melt index greater than 1 dg/min in the presence of a first catalyst composition comprising a first polymerization catalyst, the process comprising the step of:
- transitioning to a second catalyst composition to produce a second ethylene based polymer product having a density-greater than 0.920 g/cc and a melt index less than or equal to 1 dg/min, the second catalyst composition comprising the second polymerization catalyst and an additive which is a 13 metal carboxylate salt.
A process for polymerizing one or more olefins at least one of which is ethylene in the presence of a first catalyst composition to produce a first polymer product, the process comprising the steps of:
- (a) introducing the first catalyst composition comprising a first polymerization catalyst, and an additive which is a 13 metal carboxylate salt to a reactor, wherein the first catalyst composition is utilized at start-up of the process until after the process has stabilized;
- (b) discontinuing the introduction of the first catalyst composition;
- and
- (c) introducing a second polymerization catalyst substantially free of the metal carboxylate salt to the reactor to produce a second polymer product.
A continuous process for polymerizing olefin monomer(s) in a reactor under polymerization conditions, the process comprising the steps of:
- (a)introducing olefin monomer(s) to the reactor;
- (b) introducing a ( i.) polymerization catalyst;
- and (ii) a metal carboxylate salt represented by the formula MQx(OOCR)y wherein M is a 13 metal;
- Q is halogen, or a hydroxy, alkyl, alkoxy, aryloxy, siloxy, silane or sulfonate group;
- R is a hydrocarbyl radical having 8 or more carbon atoms;
- x is an integer from 0 to 2;
- y is an integer from 1 to 3;
- and the sum of x and y is equal to the valence of the metal M;
- and
- (c) withdrawing a polymer product from the reactor.
Dependencies are inferred from the claim text.