Binary cocatalyst compositions for activating heterogeneous polymerization catalysts

Claim 2

A fluid bed gas phase olefin polymerization catalyst composition, comprising a catalyst precursor and a binary cocatalyst mixture, for copolymerizing ethylene with alpha-olefins to form broad molecular weight distribution products characterized by MFR values (I 21 /I 2 ) of 35 to 60 and free of alpha-olefin oligomers, comprising activating, in a fluid bed gas phase reactor, a solid catalyst precursor with an activating amount of a cocatalyst mixture which comprises dimethylaluminum chloride and a trialkylaluminum compound in a molar ratio of dimethylaluminum chloride:trialkylaluminum compound ranging from 30:1 to 300:1; wherein the presence of trialkylaluminum eliminates the formation of alpha olefin oligomers; wherein the catalyst precursor comprises a support, which is silica, and magnesium and titanium components, wherein the catalyst precursor comprises an amount of titanium which ranges from 0.5 to 5 weight % of the catalyst precursor, wherein the catalyst precursor comprises a molar titanium to magnesium ratio which ranges from 0.2 to 1.0.

Claim 3

The catalyst composition of claim 1 prepared by a method comprising the steps of: (i) contacting a slurry of a solid, porous carrier in a non-polar solvent with at least one organomagnesium compound having the formula R m MgR' n where R and R' are the same or different C 4 -C 12 alkyl groups, m and n are each 0, 1 or 2, provided that m+n=2; and (ii) contacting said intermediate of step (i) with at least one compound selected from the group consisting of (a) SiCl 4 and (b) a silane compound of the formula (R 1 O) x SiR 2 4-x wherein x is 1 2, 3 or 4; R 1 is a hydrocarbyl group of 1 to 10 carbon atoms; and R 2 is a halogen atom or a hydrocarbyl group of 1 to 10 carbon atoms, or a hydrogen atom; (iii) contacting said intermediate of step (ii) with at least one transition metal compound in a non-polar liquid medium, the molar ratio of the said transition metal compound to said organomagnesium compound in step (i) being 0.5 to 1.5; and (iv) contacting said transition metal-containing intermediate of step (iii) with an additional quantity of an organomagnesium compound R m MgR' n where R and R' are the same or different C 4 -C 12 alkyl groups, and m+n=2, followed by drying the slurry to prepare a supported catalyst precursor.

Claim 4

A catalyst precursor of claim 2 where the porous carrier is silica and wherein R and R' are C 4 -C 10 alkyl groups.

Claim 5

A catalyst of claim 3, wherein R and R' are C 4 -C 8 alkyl groups.

Claim 6

A catalyst of claim 4, wherein R and R' are each butyl groups.

Claim 7

A catalyst of claim 2 wherein the transition metal compound is titanium tetrahalide.

Claim 8

A catalyst of claim 6 wherein the titanium tetrahalide is titanium tetrachloride.

Claim 9

The catalyst composition of claim 2, wherein the silane compound is Si(OR) 4 or Si(S"O) x (R'") 4-x wherein each of R and R" is a C 1 -C 10 hydrocarbyl group, wherein R'" is a chlorine atom, or a C 1 -C 10 hydrocarbyl group or a hydrogen atom and x=1, 2 or 3.

Claim 10

The catalyst composition of claim 1, wherein the trialkylaluminum compound is trimethylaluminum.

Claim 11

The catalyst composition of claim 1, wherein the trialkylaluminum compound is triethylaluminum.

Claim 12

The catalyst composition of claim 1, wherein the precursor is made by a method comprising the steps of: dissolving a magnesium compound and a titanium compound in a polar solvent at a titanium to magnesium molar ratio of 0.2 to 0.5; and contacting the solution with a solid, inert porous carrier and removing the solvent by drying to form a catalyst precursor.

Claim 13

A catalyst composition of claim 11 wherein the magnesium compound has the empirical formula MgX 2 wherein X is Cl, Br, I or combinations thereof.

Claim 14

A catalyst composition of claim 12 wherein the magnesium compound is MgCl 2 .

Claim 15

A catalyst composition of claim 13 wherein the titanium compound is TiCl 3 , TiCl 4 , Ti(OCCH 3 )Cl 3 , Ti(OC 3 )Cl 3 , Ti(OCOCH 3 )Cl 3 or Ti(OCOC 6 H 5 )Cl 3 .

Claim 16

A catalyst composition of claim 14 wherein the titanium compound is TiCl 3 or TiCl 4 .

Claim 17

A catalyst composition of claim 15 wherein the titanium compound is TiCl 3 .

Claim 18

The catalyst composition of claim 11, wherein the trialkylaluminum compound is trimethylaluminum.

Claim 19

The catalyst composition of claim 11, wherein the trialkylaluminum compound is triethylaluminum.