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US4972033A Expired / Lapsed US ⏱️ 0.0 years remaining

Olefin polymerization process for preparing high density or linear low density polymers of controlled molecular weight distribution

Assignee: Mobil Oil AS
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Filing: 1989-02-10
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Granted: 1990-11-20
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Expires: 2009-02-10
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Abstract

Abstract There is disclosed a catalyst composition for the polymerization of olefins, particularly alpha-olefins. The composition is prepared by synthesizing a catalyst precursor and then combining it with a conventional catalyst activator. The precursor is synthesized by: (a) contacting a solid, porous carrier with an aluminum compound; (b) contacting the resulting product with a mixture of vanadium and titanium compounds; (c) contacting the product with an alkyl ether and, (d) pre-activating the product of step (c) with a mixture of a halogenating agent and an aluminum compound. The catalyst composition is used without a halogenating agent in the polymerization medium to produce narrow molecular weight distribution HDPE and LLDPE products, or with a halogenating agent in the polymerization medium to produce broad molecular weight distribution LLDPE and HDPE products.

Inventors

  • 👤 Nemesio D. Miro

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-11-09 04:25
CPC Classifications
C; C08; C08F; C08F10/00; C08F10/02; C08F110/00; C08F110/02; C08F210/00; C08F210/16

Claims Analysis

Total Claims: 59
Claim 1
Independent Claim 255 words
A process for polymerizing at least one olefin comprising conducting the polymerization in the presence of a catalyst composition prepared by a method comprising the steps of: (I) preparing a catalyst precursor by a method comprising the steps of: (a) contacting a solid, porous carrier with an aluminum compound of the formula R.sub.k AlZ.sub.(3-k) (I) where R is a C 1 -C 10 alkyl group, Z is a halogen and k is 1, 2 or 3; (b) contacting the product of step (a) with a mixture containing a vanadium compound of the formula VO.sub.m X.sub.(n-2m) (II) where X is a halogen, m is 0 or 1 and n is 2, 3, 4 or 5, and a titanium compound of the formula TiX.sub.4 ' (III) where X' is a halogen; (c) contacting the product of step (b) with an ether selected from the group consisting of an alkyl ether having 2 to 18 carbon atoms, an alkyl/aryl ether having 2 to 18 carbon atoms, or a silane ether of the formula R"Si(OR'").sub.m R.sub.(3-m).sup.IV (IV) where R", R'" and R IV are the same or different alkyl or aryl groups and m is 1, 2 or 3; (d) pre-activating the product of step (c) with a mixture of a halogenating agent and an aluminum compound of the formula R.sub.n 'AlX.sub.(3-n) " (V) where R' is a C 1 -C 10 alkyl group, X" is a halogen and n is 1, 2 or 3; and (II) activating the precursor by combining it with an olefin polymerization catalyst activator.
Claim 2
Dependent Claim 255 words
A process for polymerizing at least one olefin comprising conducting the polymerization in the presence of a catalyst composition prepared by a method comprising the steps of: (I) preparing a catalyst precursor by a method comprising the steps of: (a) contacting a solid, porous carrier with an aluminum compound of the formula R.sub.k AlZ.sub.(3-k) (I) where R is a C 1 -C 10 alkyl group, Z is a halogen and k is 1, 2 or 3; (b) contacting the product of step (a) with a mixture containing a vanadium compound of the formula VO.sub.m X.sub.(n-2m) (II) where X is a halogen, m is 0 or 1 and n is 2, 3, 4 or 5, and a titanium compound of the formula TiX.sub.4 ' (III) where X' is a halogen; (c) contacting the product of step (b) with an ether selected from the group consisting of an alkyl ether having 2 to 18 carbon atoms, an alkyl/aryl ether having 2 to 18 carbon atoms, or a silane ether of the formula R"Si(OR'").sub.m R.sub.(3-m).sup.IV (IV) where R", R'" and R IV are the same or different alkyl or aryl groups and m is 1, 2 or 3; (d) pre-activating the product of step (c) with a mixture of a halogenating agent and an aluminum compound of the formula R.sub.n 'AlX.sub.(3-n) " (V) where R' is a C 1 -C 10 alkyl group, X" is a halogen and n is 1, 2 or 3; and (II) activating the precursor by combining it with an olefin polymerization catalyst activator.
Claim 3
Dependent Claim 15 words
A process of claim 1 wherein R is a C 2 -C 5 alkyl group.
Claim 4
Dependent Claim 11 words
A process of claim 2 wherein R is an ethyl group.
Claim 5
Dependent Claim 9 words
A process of claim 3 wherein k is 3.
Claim 6
Dependent Claim 21 words
A process of claim 4 wherein X and X' are each the same or different and they are bromine or chlorine.
Claim 7
Dependent Claim 12 words
A process of claim 5 wherein X and X' are each chlorine.
Claim 8
Dependent Claim 15 words
A process of claim 6 wherein R' is a C 2 -C 5 alkyl group.
Claim 9
Dependent Claim 11 words
A process of claim 7 wherein R' is an ethyl group.
Claim 10
Dependent Claim 11 words
A process of claim 8 wherein X" is bromine or chlorine.
Claim 11
Dependent Claim 17 words
A process of claim 9 wherein the ether is a cyclic alkyl ether or a silane ether.
Claim 12
Dependent Claim 50 words
A process of claim 10 wherein the ether is a cyclic alkyl ether having 2 to 7 carbon atoms or a silane ether of the formula R"Si(OR'").sub.m R.sup.IV where R", R'" and R IV are the same or different alkyl or aryl groups and m is 1, 2 or 3.
Claim 13
Dependent Claim 27 words
A process of claim 11 wherein R" is an aryl group and R'" and R IV are the same or different C 1 -C 4 alkyl groups.
Claim 14
Dependent Claim 12 words
A process of claim 12 wherein the ether is tetrahydrofuran or phenyltrimethoxysilane.
Claim 15
Dependent Claim 17 words
A process of claim 13 wherein the halogenating agent is a silicon halide or a hydrocarbyl halide.
Claim 16
Dependent Claim 13 words
A process of claim 14 wherein the halogenating agent is a hydrocarbyl halide.
Claim 17
Dependent Claim 17 words
A process of claim 15 wherein the halogenating agent is carbon tetrachloride, chloroform, 1,1,1-trichloroethane, dichloromethane or trichlorofluoromethane.
Claim 18
Dependent Claim 14 words
A process of claim 16 wherein the halogenating agent is carbon tetrachloride or chloroform.
Claim 19
Dependent Claim 11 words
A process of claim 17 wherein the halogenating agent is chloroform.
Claim 20
Dependent Claim 16 words
A process of claim 18 wherein the vanadium compound of the formula (II) is vanadium oxytrichloride.
Claim 21
Dependent Claim 89 words
A process of claim 19 wherein in the mixture used in said step (b), the molar ratio of the elemental vanadium (V), derived from the vanadium compound of the formula (II), per unit weight of the carrier is about 0.3 to about 1.0 mmoles of V per gram of the carrier, and the molar ratio of the elemental titanium (Ti), derived from the titanium compound of the formula (III), per unit weight of the carrier is about 0.05 to about 0.7 mmoles of Ti per gram of the carrier.
Claim 22
Dependent Claim 57 words
A process of claim 20 wherein the molar ratio of V per unit weight of the carrier is about 0.6 to about 1.0 mmole of V per gram of the carrier and the molar ratio of Ti per unit weight of the carrier is about 0.1 to about 0.25 mmole of Ti per gram of the carrier.
Claim 23
Dependent Claim 15 words
A process of claim 21 wherein the molar ratio of V to Ti is 5:1.
Claim 24
Dependent Claim 10 words
A process of claim 22 wherein the ether is tetrahydrofuran.
Claim 25
Dependent Claim 23 words
A process of claim 23 wherein the amount of the tetrahydrofuran is about 0.5 to about 1.3 mmoles per gram of the carrier.
Claim 26
Dependent Claim 23 words
A process of claim 24 wherein the amount of the tetrahydrofuran is about 0.75 to about 1.0 mmoles per gram of the carrier.
Claim 27
Dependent Claim 17 words
A process of claim 25 wherein the molar ratio of the tetrahydrofuran to V is about 1.0.
Claim 28
Dependent Claim 20 words
A process of claim 26 conducted without a halogenating agent to produce narrow molecular weight distribution HDPE or LLDPE polymers.
Claim 29
Dependent Claim 20 words
A process of claim 26 conducted with a halogenating agent to produce broad molecular weight distribution HDPE or LLDPE polymers.
Claim 30
Dependent Claim 40 words
A process of claim 28 wherein the halogenating agent has the formula MH.sub.n X'".sub.(p-n) where M is Si, C, Ge or Sn, X'" is a halogen, n is 0, 1, 2 or 3 and p is the valence of M.
Claim 31
Dependent Claim 13 words
A process of claim 29 wherein the halogenating agent is CHCl 3 .
Claim 32
Dependent Claim 33 words
A process of claim 30 wherein the halogenating agent is used in the amount of 0 to 65 ppm to produce polymers having melt flow ratio (MFR) of about 25 to about 80.
Claim 33
Dependent Claim 30 words
A process of claim 30 wherein the halogenating agent is used in the amount of 90 to 300 ppm to produce polymers having MFR of about 80 to about 120.
Claim 34
Dependent Claim 32 words
A process of claim 1 wherein the catalyst activator is at least one compound of the elements of Group IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements.
Claim 35
Dependent Claim 13 words
A process of claim 33 wherein the catalyst activator is an organometallic compound.
Claim 36
Dependent Claim 32 words
A process of claim 30 wherein the catalyst activator is at least one compound of the elements of Group IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements.
Claim 37
Dependent Claim 13 words
A process of claim 35 wherein the catalyst activator is an organometallic compound.
Claim 38
Dependent Claim 13 words
A process of claim 36 wherein the catalyst activator is a metal alkyl.
Claim 39
Dependent Claim 24 words
A process of claim 37 wherein the catalyst activator is a Group IIIB metal alkyl having 1 to 20 carbon atoms per alkyl radical.
Claim 40
Dependent Claim 21 words
A process of claim 38 wherein the activator is a trialkylaluminum compound having 1 to 6 carbon atoms per alkyl radical.
Claim 41
Dependent Claim 15 words
A process of claim 39 producing LLDPE polymers wherein the activator is trimethylaluminum or triethylaluminum.
Claim 42
Dependent Claim 10 words
A process of claim 40 wherein the activator is trimethylaluminum.
Claim 43
Dependent Claim 13 words
A process of claim 39 producing HDPE polymers wherein the activator is triethylaluminum.
Claim 44
Dependent Claim 32 words
A process of claim 27 wherein the catalyst activator is at least one compound of the elements of Group IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements.
Claim 45
Dependent Claim 13 words
A process of claim 43 wherein the catalyst activator is an organometallic compound.
Claim 46
Dependent Claim 13 words
A process of claim 44 wherein the catalyst activator is a metal alkyl.
Claim 47
Dependent Claim 24 words
A process of claim 45 wherein the catalyst activator is a Group IIIB metal alkyl having 1 to 20 carbon atoms per alkyl radical.
Claim 48
Dependent Claim 21 words
A process of claim 46 wherein the activator is a trialkylaluminum compound having 1 to 6 carbon atoms per alkyl radical.
Claim 49
Dependent Claim 15 words
A process of claim 47 producing LLDPE polymers wherein the activator is trimethylaluminum or triethylaluminum.
Claim 50
Dependent Claim 10 words
A process of claim 48 wherein the activator is trimethylaluminum.
Claim 51
Dependent Claim 13 words
A process of claim 47 producing HDPE polymers wherein the activator is triethylaluminum.
Claim 52
Dependent Claim 13 words
A process of claim 36 wherein the catalyst activator is a metal hydride.
Claim 53
Dependent Claim 14 words
A process of claim 36 wherein the catalyst activator is a metal alkyl hydride.
Claim 54
Dependent Claim 14 words
A process of claim 36 wherein the catalyst activator is a metal alkyl halide.
Claim 55
Dependent Claim 23 words
A process of claim 53 wherein the catalyst activator is a metal dialkyl halide having 1 to 20 carbon atoms per alkyl radical.
Claim 56
Dependent Claim 13 words
A process of claim 44 wherein the catalyst activator is a metal hydride.
Claim 57
Dependent Claim 14 words
A process of claim 44 wherein the catalyst activator is a metal alkyl hydride.
Claim 58
Dependent Claim 14 words
A process of claim 45 wherein the catalyst activator is a metal alkyl halide.
Claim 59
Dependent Claim 23 words
A process of claim 56 wherein the catalyst activator is a metal dialkyl halide having 1 to 20 carbon atoms per alkyl radical.

USPTO Annuity & Maintenance Windows

Annuity Stage Window Opens Payment Deadline Surcharge Period Until Estimated Fee Status
3.5 Years (Year 4) 1993-11-19 1994-05-21 1994-11-20 $2000.00 Window Closed / Lapsed
7.5 Years (Year 8) 1997-11-19 1998-05-21 1998-11-20 $3760.00 Window Closed / Lapsed
11.5 Years (Year 12) 2001-11-19 2002-05-21 2002-11-20 $7700.00 Window Closed / Lapsed

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