Polymerization catalyst and process

Claim 2

A polymerization catalyst comprising, in combination, (a) chromium oxide; (b) a silica support; (c) titanium dioxide, titanium being present in an amount within the range of about 3.0 to about 4.0 weight percent based on the weight of components a, b and c; and (d) an organoboron compound of the formula BR 3 wherein each R is selected independently from hydrogen, alkyl, cycloalkyl and aryl, at least one R is a hydrocarbon radical having from 1 to 12 carbon atoms, and the total number of carbon atoms in the organoboron compound does not exceed 30.

Claim 3

The polymerization catalyst of claim 1 in which at least a portion of the chromium is in the hexavalent state.

Claim 4

The polymerization catalyst of claim 2 in which chromium is present in an amount of from about 0.001 to about 10.0 weight percent based on the weight of components a, b, and c.

Claim 5

The polymerization catalyst of claim 1 in which the organoboron compound is selected from the group consisting of trimethylborane, triethylborane, tri-n-dodecylborane, tricyclohexylborane, tri(2-methylcyclopentyl)borane, triphenylborane, tribenzylborane, tri(2-ethylphenyl)borane, and methyldiethylborane.

Claim 6

The polymerization catalyst of claim 3 in which the organoboron compound is triethylborane and the chromium is present in an amount within the range of about 0.1 to about 5 weight percent.

Claim 7

The polymerization catalyst of claim 1 in which the organoboron compound is present in an amount within the range of about 0.3 to about 15 weight percent based on the weight of components a, b and c.

Claim 8

The polymerization catalyst of claim 6 in which the organoboron compound is present in an amount within the range of about 0.5 to about 13 weight percent based on the weight of components a, b and c.

Claim 9

The polymerization catalyst of claim 2 which further comprises a minor amount of a compound selected from the group consisting of alumina, thoria, and zirconia.

Claim 10

A polymerization catalyst prepared by a method comprising contacting, under particle-form polymerization conditions in a polymerization reactor, in the presence of at least one polymerizable monomer a first catalyst component comprising a silica support containing chromium oxide at least a portion of which is in the hexavalent state and titanium dioxide, titanium being present in an amount within the range of about 3 weight percent to about 10 weight percent based on the weight of the first catalyst component, with a second catalyst component comprising an organoboron compound represented by the formula BR 3 wherein each R is selected independently from hydrogen, alkyl, cycloalkyl and aryl, at least one R is a hydrocarbon radical having from 1 to 12 carbon atoms, and the total number of carbon atoms in the organoboron compound does not exceed 30.

Claim 11

A polymerization catalyst prepared by a method comprising contacting, under particle-form polymerization conditions in a polymerization reactor, in the presence of at least one polymerizable monomer a first catalyst component comprising a silica support containing chromium oxide at least a portion of which is in the hexavalent state and titanium dioxide, titanium being present in an amount within the range of about 3 weight percent to about 10 weight percent based on the weight of the first catalyst component, with a second catalyst component comprising an organoboron compound represented by the formula BR 3 wherein each R is selected independently from hydrogen, alkyl, cycloalkyl and aryl, at least one R is a hydrocarbon radical having from 1 to 12 carbon atoms, and the total number of carbon atoms in the organoboron compound does not exceed 30.

Claim 12

The polymerization catalyst of claim 9 in which the organoboron compound is selected from triethylboron and triphenylboron.

Claim 13

The polymerization catalyst of claim 9 in which chromium is present in an amount of from about 0.1 to about 5 weight percent based on the weight of the first catalyst component.

Claim 14

The polymerization catalyst of claim 11 in which the titanium is present in an amount within the range of about 3.0 to about 4.0 weight percent.

Claim 15

The polymerization catalyst of claim 12 in which the first and second catalyst components are contacted in the presence of ethylene monomer at a temperature within the range of about 60° to about 110° C. and a pressure within the range of about 1.7 to about 4.1 MPa.

Claim 16

The polymerization catalyst of claim 13 in which the second catalyst component further comprises a hydrocarbon diluent.

Claim 17

The polymerization catalyst of claim 14 in which the second catalyst component consists essentially of the organoboron compound and the hydrocarbon diluent.

Claim 18

The polymerization catalyst of claim 15 in which the ethylene monomer is present in a hydrocarbon diluent and the organoboron compound is present in an amount within the range of about 0.1 to about 12 ppm based on the amount of hydrocarbon diluent.

Claim 19

The polymerization catalyst of claim 13 in which the first and second catalyst components are contacted in the presence of at least one comonomer selected from 1-butene, 1-hexene, 1,3-butadiene and propylene.

Claim 20

The polymerization catalyst of claim 16 in which the organoboron compound is triethylborane present in an amount of about 3 ppm.

Claim 21

The polymerization catalyst of claim 16 in which the organoboron compound is triethylboron present in an amount of about 4 ppm.

Claim 22

The polymerization catalyst of claim 1, 9 or 12 in which the first catalyst component is prepared by a process comprising: contacting a chromium-containing silica xerogel in a fluidized bed in the presence of nitrogen gas at a temperature of from about 100° to about 200° C. with a titanium compound so as to incorporate the titanium compound into the silica xerogel and heating the thus-treated silica xerogel in a substantially dry oxygen-containing atmosphere at a temperature of from about 400° to about 1000° C. for at least about ten minutes.

Claim 23

The polymerization catalyst of claim 20 in which the titanium compound is titanium tetraisopropoxide.

Claim 24

A polymerization process comprising contacting at least one polymerizable olefin monomer under polymerization conditions with the catalyst of claim 1, 2, 3, 4, 5, 6, 7 or 8.

Claim 25

A polymerization process comprising contacting ethylene monomer with a first catalyst component comprising a silica support, chromium oxide at least part of which is in the hexavalent state, and titania, the amount of titanium in the first catalyst component being within the range of about 3 weight percent to about 10 weight percent based on the weight of the first catalyst component, and a second catalyst component consisting essentially of an organoboron compound of the formula BR 3 wherein each R is selected independently from hydrogen, alkyl, cycloalkyl and aryl, at least one R is a hydrocarbon radical having from 1 to 12 carbon atoms, and the total number of carbon atoms in the organoboron compound does not exceed 30 in an inert diluent at a temperature within the range of 20° to 200° C.

Claim 26

A polymerization process comprising contacting ethylene monomer with a first catalyst component comprising a silica support, chromium oxide at least part of which is in the hexavalent state, and titania, the amount of titanium in the first catalyst component being within the range of about 3 weight percent to about 10 weight percent based on the weight of the first catalyst component, and a second catalyst component consisting essentially of an organoboron compound of the formula BR 3 wherein each R is selected independently from hydrogen, alkyl, cycloalkyl and aryl, at least one R is a hydrocarbon radical having from 1 to 12 carbon atoms, and the total number of carbon atoms in the organoboron compound does not exceed 30 in an inert diluent at a temperature within the range of 20° to 200° C.

Claim 27

The polymerization process of claim 23 in which the titanium is present in the first catalyst component in an amount within the range of about 3.0 to about 4.0 weight percent.

Claim 28

The polymerization process of claim 23 in which the titanium is present in the first catalyst component in an amount within the range of about 3.0 to about 4.0 weight percent and the organoboron compound is triethylborane.

Claim 29

The polymerization process of claim 23 in which the resulting polymer has a density of at least 0.960 g/cc.

Claim 30

The polymerization process of claim 23 in which the polymerization is conducted in a continuous particle-form process.

Claim 31

The polymerization process of claim 27 in which the polymerization is conducted in a loop reactor.

Claim 32

The polymerization process of claim 28 in which the organoboron compound is introduced into the loop reactor in an amount of about 0.3 to about 15 weight percent based on the weight of the first catalyst component.

Claim 33

The polymerization process of claim 28 in which the organoboron compound is introduced into the loop reactor in an amount of about 0.1 to about 12 ppm based on the amount of inert diluent charged per hour.

Claim 34

The polymerization process of claim 23 or 30 in which the inert diluent is isobutane.

Claim 35

The polymerization process of claim 23, 25, 26, 27 or 30 in which ethylene is copolymerized with a monomer selected from copolymerizable 1-olefins and conjugated diolefins.

Claim 36

The polymerization process of claim 23 in which the first catalyst component further comprises a minor amount of a compound selected from alumina, thoria and zirconia.