Catalyst compositions, polymerization processes, and polymers produced in these processes

Catalyst compositions, polymerization processes and polymers produced by these processes

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Technical field

The present invention relates to a catalyst composition comprising a metal compound comprising a Group 15 element and a mixed catalyst composition comprising at least two metal compounds. In a preferred embodiment, at least one of the metal compounds constituting said catalyst composition is a metal compound comprising a Group 15 element. In an even more preferred embodiment, the further metal compound is a sterically bulky ligand metallocene-based catalyst compound. Furthermore, the present invention relates to catalyst systems based on said compositions and their use in the polymerization of olefin (s). Furthermore, the present invention relates to a novel polyolefin, usually polyethylene, in particular a multimodal polymer, in particular a bimodal polymer, and its use in various end products such as film, molded article and tube.

BACKGROUND OF THE INVENTION

Advances in polymerization and catalysis have made it possible today to produce new polymers having improved physical and chemical properties that are suitable for use in a wide range of products and applications with superior properties. Along with the development of new catalysts, there has been a great expansion in the choice of a possible type of polymerization (ie solution, slurry, high pressure, or gas phase) suitable for the production of a particular polymer. Advances in polymerization have also made more efficient, highly productive and cost-effective processes available. These advances can be illustrated, in particular, by the development of technology using metallocene-based catalyst systems with sterically bulky ligands.

The results of recent research have led to the discovery of anionic, multidentate heteroatom ligands, which have been described in the following publications: (1) Kempe et al., "Aminopyridinato Ligands - New Directions and Limitations,

80^th Canadian Society for Chemistry Meeting, Windsor, Ontario, Canada, 1-4 June 1997; (2) Kempe et al., Inorg. Chem., 1996, 35, 6742; (3) Bei, X .; Swenson, DC; Jordan, RF Organometallics, 1997, 16, 3282; (4) Horton et al., "Cationic Alkylzirconium Complexes Based on a Tridentate Diamide Ligand: New Alkene Polymerization Catalysts, Organomettalics, 1996, 15, 2672-2674, concerning tridentate zirconium complexes; (5) Baumann et al., "Synthesis of Titanium and Zirconium Complexes that Contain the Tridentate Diamido Ligand [((t-Bu-d₆) NIGHT₆H₄) ₂0] ²"{[NON]}²Living Polymerization of 1-Hexene by Activated [NON] ZrMe2, Journal of the American Chemical Society, 119, 3830-3831; (6) Cloke et al., "Zirconium Complexes Incorporating the New Tridentate Diamide Ligand [(Me3Si) N {CH 2 CH 2 N (Sime3)} 2]^2_ (L); The Crystal Structure of Zr (BH4)₂L] and [ZrCl {CH (SiMe₃) ₂} L], J. Chem. Soc. Dalton Trans., 1995, 25-30; (7) Clark et al., "Titanium (IV) Complexes Incorporating the Aminodiamide Ligand [(SiMe₃) N {CH₂CH₂N (SiMe₃) }₂] ²~ (L); The X-ray Crystal Structure of [TiMe₂(L)] and [TiCl 2 CH (SiMe₃) ₂(L)], Journal of

Organometallic Chemistry, 1995, 50, 333-340; (8) Scollard and you

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collaborators, &amp; quot; Living Polymerization of Alpha-Olefins by Chelating Diamide Complexes of Titanium, J. Am. Chem. Soc., 1996, 118, 10008-10009; and (9) Guerin et al., Conformationally Rigid Diamide Complexes: Synthesis and Structure of Titanium (IV) Alkyl Derivatives,

Organometallics, 1996, 15, 5085-5089.

In addition, U.S. Patent No. 5,576,460 describes the preparation of arylamine ligands, and U.S. Patent No. 5,889,128 discloses a process for olefin polymerization which produces so-called living polymers (i.e., end-chain active polymers), and wherein a metal atom and a ligand containing two atoms of the 15th element and one atom of the 16th element of the Periodic Table or three atoms of the 15th element are used. groups of the periodic system of elements. European Patent Application Publication No. EP 893 454 also describes preferred amide compounds containing titanium as a transition metal. In addition, U.S. Patent No. 5,318,935 discusses amide compounds of transition metals and catalyst systems based on these compounds, which are particularly useful for producing isotactic polypropylene. Polymerization catalysts containing bidentate and tridentate ligands are further described in U.S. Patent No. 5,506,184.

The use of traditional bulky ligand metallocene catalyst systems results in polymers which are sometimes difficult to form into a film, for example using an old extruder. One possibility of improving the properties of these polymers is to mix these polymers with other polymers to form a blend that has the desired properties that the individual components would have used alone. Although the two-component polymer blends are easier to process, they are expensive to manufacture and result in the inclusion of a relatively cumbersome mixing stage in the manufacturing / processing process.

The higher molecular weight imparts the desired mechanical properties to the polymer and results in stable sleeve formation in the film production. However, this property also prevents extrusion processing of the polymers by increasing the back pressure in the extruders during processing, promotes melt fracture when the sleeve is stretched, and potentially promotes the formation of too high a degree of orientation in the resulting film. Said anionic, multidentate, heteroatom-containing catalyst systems tend to form very high molecular weight polymers. This problem can be solved by simultaneously forming a secondary, minor component of lower molecular weight, which serves to reduce back pressure in the extruder and prevent melt fracture. Several industrial processes are based on this principle, using several reactors for the production of high density polyethylene (HDPE) with bimodal molecular weight distribution (MWD). The worldwide standard in this regard is the HDPE product of Mitsui Chemicals, sold under the designation HIZEX®, and HIZEX® is produced by an expensive process using two or more reactors.

Another approach to solving the above problem is the simultaneous production of two different polymers in one reactor by using two different catalysts in this reactor. In «« »· · · · · · · · · · · · · · · · · · · · · · · · · · · · · WO 99/03899 discloses the use of a typical sterically bulky ligand metallocene catalyst and a conventional Ziegler-Natta catalyst in a single reactor to produce bimodal polyolefins. However, the use of two different types of catalysts results in the formation of a polymer whose properties cannot be predicted on the basis of the properties of the polymers that would have arisen if the individual catalysts were used separately. This unpredictability of the properties of the resulting polymer is due, for example, to competitive reactions or to other influences between the catalysts or catalyst systems used.

Higher density and molecular weight polyethylenes are used in the production of films having high rigidity, toughness and high overall strength. Such polymers are also used in the manufacture of pipes, where the pipes need to have good rigidity, toughness, long life and, in particular, to be resistant to cracking caused by ambient loads.

Accordingly, there is a need for improved catalyst compounds and a catalyst mixture that can be used to produce processable polyethylene polymers, preferably in a single reactor, characterized by a desirable combination of processability, mechanical and optical properties.

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SUMMARY OF THE INVENTION

The present invention relates to catalyst compounds, catalyst systems and mixed catalyst systems, polymers produced using these compounds and systems, and products made from such polymers.

One aspect of the present invention is a metal catalyst compound comprising a Group 15 element, a mixed catalyst composition comprising at least two metal compounds, wherein at least one of said metal compounds is a metal compound comprising a Group 15 element and another compound the metal is a metallocene with a sterically bulky ligand, and a conventional transition metal catalyst or mixture thereof. Furthermore, the invention relates in this aspect to catalyst systems comprising said catalysts, their use in the polymerization of one or more olefins and the polymers thus produced.

Another aspect of the invention is a catalytic compound of a Group 3 to 14 metal group comprising a Group 15 element in which said group 3 to 14 metal is preferably from 3 to 7 a group of the Periodic Table of the Elements, more preferably from Groups 4 to 6 of the Periodic Table of the Elements, and even more preferably of Group 4. a bi- or tridentate ligand substituted group, a mixed catalyst composition comprising at least two metal compounds, wherein at least one metal compound is the above-described metal compound comprising a Group 15 element, and wherein the other compound is

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9999 9* 9999 99 99

9 9 9 9 9 *9»

999 999

9999 9,999,999 sterically bulky ligand metallocene metal, and a conventional transition metal catalyst or mixture thereof. Furthermore, the invention relates in this aspect to catalyst systems comprising said catalysts, their use in the polymerization of one or more olefins and the polymers thus produced. In this embodiment, it is preferred that the other metal compound is a sterically bulky ligand metallocene.

Another aspect of the present invention is a catalytic compound in which a Group 3 to 14 metal atom is bound to at least one leaving group and further to at least two Group 15 atoms, at least one of these atoms is also bound via an additional group to the atom of the element of 15. or

16. a mixed catalyst composition comprising at least two metal compounds, wherein at least one metal compound is a metal compound as described above comprising a Group 15 element, and wherein the second metal compound differs from the first metal compound, the metal compound is a sterically bulky ligand metallocene, and a conventional transition metal catalyst or mixture thereof. Furthermore, the invention relates in this aspect to catalyst systems comprising said catalysts, their use in the polymerization of one or more olefins and the polymers thus produced.

Another aspect of the present invention is a method of applying the above-described catalyst compositions to a suitable support, catalyst systems alone supported on a suitable support, and their use in polymerizing one or more olefins.

·♦·» ·· »♦·· ·· 00 0 4 0 0* 0 000» • 0 000 00 0 • 0 « 0 0 0 0 · 0 0 • 0 000 «00

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Another aspect of the present invention is the use of an aluminum-containing Lewis acid activating agent together with the catalyst compositions and systems of the invention.

Another aspect of the present invention is a process for injecting the catalyst compositions and systems of the present invention contained in a liquid carrier into a polymerization reactor.

Another aspect of the present invention is a process for the polymerization of one or more olefins in gas phase or in suspension, using any of the catalyst systems described herein or any of the supported catalyst systems described herein.

A further aspect of the present invention is a process for the polymerization of one or more olefins using the catalyst compositions described above, in particular in a single polymerization reactor. More preferably, the process utilizes a single continuous gas phase reactor to form a multimodal polymer.

Another aspect of the invention are polymers produced using the above mixed catalyst composition, in particular novel high density polyethylenes with a bimodal molecular weight distribution (also referred to below as HDPE with bimodal MWD).

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The present invention relates to the use of a catalytic metal compound comprising a Group 15 element of the Periodic Table of the Elements in the polymerization of one or more olefins. In addition, it has been found that the use of these catalytic metal compounds containing a Group 15 element in combination with another catalyst, preferably a metallocene with a sterically bulky ligand, results in the formation of HDPE with a bimodal MWD. Unexpectedly, it has been found that the mixed catalyst composition of the present invention can be used in a single reactor system.

A metal compound containing a Group 15 element

A compound comprising a group 15 element of the Periodic Table of the Invention typically comprises a metal atom of Group 3-14, preferably Group 3 to 7, more preferably Group 4-6. element and most preferably from group 4 of the Periodic Table of the Elements, which is bound to at least one leaving group and further to at least two atoms of the elements of 15. group of the Periodic Table of the Elements, wherein at least one of these atoms is simultaneously attached to an atom of an element of the 15th or 16th group of the Periodic Table by another group.

In one embodiment of the present invention, at least one of the atoms of the 15th element of the Periodic Table of the Elements is bound to the atom of the 15th or 16th element of the Periodic Table of Elements through another group, which further group may be a hydrocarbon group containing Carbon atoms, a group containing a heteroatom, silicon, germanium, tin, lead or phosphorus, wherein the atom of the element of 15 or 16 . also, it may not be bound to any group or may be bound to a hydrogen atom, a group containing an element of the 14th element of the periodic group, a halogen atom, or a group containing a heteroatom, each of the 15 atoms of the elements. The groups of the Periodic Table of the Elements may also be bonded to a cyclic group and may optionally be bonded to a hydrogen, halogen, heteroatom or hydrocarbon group, or to a heteroatom containing group.

In another embodiment of the present invention, the structure of a metal compound comprising a Group 15 element may be represented by Formula I or II

R⁴

Rt

R⁶

R 3 -L 4 R²-7/

MⁿX n + m

R7

R5 (i) or

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(II) 99 99

9 9 9 9 9 * 9 9

9 9 9 9 9 9 9

9 9 9 9 9 9

9 9 9 9 9 999999 where

M is a Group 3 to 12 transition metal atom or a Group 13 or 14 metal atom, preferably a Group 4, 5 or 6 metal atom, more preferably a metal atom 4. a group of the Periodic Table of the Elements, most preferably a zirconium, titanium or hafnium atom;

X are leaving groups which may be the same or different, preferably anionic leaving groups, more preferably are independently selected from hydrogen, hydrocarbon, heteroatom or halogen, most preferably represent alkyl groups;

y is 0 or 1 (if y is 0 then L 'is absent);

n is the oxidation state of the metal M, preferably +3, +4 or +5, more preferably +4;

m is the formal charge of YZL or YZL ', preferably 0.1,

-2 or -3, more preferably -2;

L is an element of a group 15 or 16 element of the periodic table, preferably a nitrogen atom;

L 'is an element of a group 15 or 16 element or a group comprising an element of a group 14 element, preferably a carbon, silicon or germanium atom;

• to * · to this

Y is an element of a Group 15 element, preferably a nitrogen or phosphorus atom, more preferably a nitrogen atom;

Z is a Group 15 element, preferably a nitrogen or phosphorus atom, more preferably a nitrogen atom;

R¹ and R² are independently selected from the group consisting of a hydrocarbon group containing from 1 to 20 carbon atoms, a group containing a heteroatom and up to 20 carbon atoms, a silicon atom, a germanium atom, a tin atom, a lead atom or a phosphorus atom; 2 to 20 carbon atoms, an aryl group or an arylalkyl group, more preferably from the group consisting of a linear, branched or cyclic alkyl group containing from 2 to 20 carbon atoms, most preferably from the group consisting of hydrocarbon groups containing from 2 to 6 carbon atoms;

R³ is absent or is selected from the group consisting of a hydrocarbon group, a hydrogen atom, a halogen atom, a heteroatom-containing group, preferably from the group consisting of a linear, cyclic or branched alkyl group containing from 1 to 20 carbon atoms, more preferably not R³ present or selected from the group consisting of hydrogen and alkyl, most preferably is hydrogen;

R⁴ and R⁵ are independently selected from the group consisting of an alkyl group, an aryl group, substituted with an alkyl group, an aryl group, and substituted by an alkyl group, an aryl group, and a substituted group; This aryl group, a cyclic alkyl group, a substituted cyclic alkyl group, a cyclic arylalkyl group, a substituted cyclic arylalkyl group, and a polycyclic system preferably containing up to 20 atoms carbon, more preferably from 3 to 10 carbon atoms, even more preferably from the group consisting of a hydrocarbon group having from 1 to 20 carbon atoms, an aryl group having from 1 to 20 carbon atoms, an arylalkyl group having from 1 to 20 carbon atoms, and a heteroatom containing group such as a PR group₃wherein R represents an alkyl group;

wherein R¹ and R² may be joined together and / or R⁴ and R⁵ they may be linked together;

R⁶ and R⁷ are not independently present or are independently selected from the group consisting of hydrogen, alkyl, halogen, heteroatom and hydrocarbon, preferably linear, cyclic or branched alkyl groups containing from 1 to 20 carbon atoms, more preferably not groups present; and

R * is either absent or selected from the group consisting of hydrogen, a group containing an element of a group 14 element of the Periodic Table, a halogen atom, and a group containing a heteroatom.

The term "formal charge of YZL or YZL '" refers to the charge of the entire ligand in the absence of said metal and leaving groups X.

• ·· ···· 44 44

9 9 9 9 9 4 9 9

9 9 9 9 i 9 4

9 9 9 9 9 9

999 9 99 9 99 9994

The term "R¹ and R² they may be joined together to mean that the groups R 1¹ and R² they may be directly bonded to each other or may be bonded to each other through other groups. The term "R⁴ and R⁵ they may be joined together to mean that the groups R 1⁴ and R⁵ they may be directly bonded to each other or may be bonded to each other through other groups.

By alkyl is meant linear or branched alkyl groups, or alkenyl groups, alkynyl groups, cycloalkyl groups or aryl groups, acyl groups, aroyl groups, alkoxy groups, aryloxy groups, alkylthio groups, dialkylamino groups, alkoxycarbonyl groups, aryloxycarbonyl groups, aryloxycarbonyl groups, aryloxycarbonyl groups, , alkyl- or dialkylcarbamoyl groups, acyloxy groups, acylamino groups, aroylamino groups, linear, branched or cyclic alkylene groups or combinations thereof. Arylalkyl means herein a substituted aryl group.

In a preferred embodiment, R is⁴ and R⁵independently of one another, a group of formula 1

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Relation to Z or Y • «··· 4« 4 · «4 44 44

4 44 4 44««

4 444 44 4

444 444

4444 44 4 444444 where

R⁸ to R¹² are independently selected from the group consisting of hydrogen, alkyl of 1 to 40 carbon atoms, halogen, heteroatom, heteroatom of up to 40 carbon atoms, preferably from the group consisting of linear or branched alkyl of 1 to 20 atoms carbon, preferably methyl, ethyl, propyl or butyl, or any two of R 1⁸to R¹² may together form a cyclic group and / or a heterocyclic group, wherein said cyclic groups may be aromatic.

In a preferred embodiment of the invention, the groups R are⁹, R¹⁰and R¹² independently selected from the group consisting of methyl, ethyl, propyl or butyl (including all isomers). In an even more preferred embodiment, R is⁹, R¹⁰ and R¹² methyl and R groups⁸ and R¹¹ represent hydrogen atoms.

In a particularly preferred embodiment of the present invention the groups R are⁴ and R⁵ groups of formula 2

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(2)

CH₃ * * * * * * * * * * * * * * * * * * * * * * * · · · · · · · · · · · · · · · · · · · · · · · · ·

In this embodiment, the group M represents an element of a Group 4 element, preferably zirconium, titanium or hafnium, more preferably zirconium; L, Y and Z are each nitrogen; both R groups¹ and R² are -CH 2 -CH 2 -; skupina R³represents hydrogen; and R groups⁶ and R⁷ are not present.

In another preferred embodiment of the invention, at least one X group is a substituted hydrocarbon group, preferably a substituted alkyl group having more than 6 carbon atoms, more preferably an aryl group substituted with an alkyl group. The most preferred aryl group substituted with an alkyl group is a benzyl group.

In a particularly preferred embodiment of the present invention, the structure of the metal-containing compound and the Group 15 element can be represented by Formula A

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(AND)

4444 ·· «··· ·· ·· · · · 4444

4 4 4 4 4 • • 4 4 4 «4444

In this formula, Ph refers to a phenyl group.

Metal compounds containing a Group 15 element atom are prepared by known methods, such as those described in European Patent Application Publication No. EP 0 893 454, US Patent No. 5,889,128, and reference materials cited in the US Patent No. 5,889,128, the contents of which are incorporated herein by reference. U.S. Patent Application Ser. No. 09 / 312,878, filed July 17, 1999; on May 1, 1999, a gas phase or slurry polymerization process using a supported supported bisamide catalyst is disclosed, the disclosure of which is also incorporated herein by reference.

A preferred method for the direct synthesis of these compounds comprises reacting a neutral ligand (see, for example, the group YZL or YZL 'in formula I or II) with MⁿX_nwherein M is a metal atom of 3 to 14. n of the Periodic Table of the Elements, n is the oxidation state of the metal M, and each X represents an anionic group, such as a halide, in a non-coordinating or weakly coordinating solvent such as ether, toluene, xylene, benzene, dichloromethane and / or hexane; whose boiling point is above 60 ° C, at a temperature of about 20 ° C to about 150 ° C (preferably at a temperature of 20 ° C to 100 ° C), preferably for at least 24 hours, and subsequently reacting the resulting mixture with an excess (such as four or more equivalents) of an alkylating agent such as methyl magnesium bromide in ether. The resulting magnesium salts are formed from

00 The 4,404 mixtures are removed by filtration and the metal complex formed is isolated by standard procedures.

In one embodiment of the present invention, a metal compound containing a Group 15 element atom is prepared by a method comprising reacting a neutral ligand (see, for example, YZL or YZL 'in Formula 1 or 2) with a compound of Formula MⁿX_n (wherein M is a Group 3 to 14 metal atom, n is the oxidation state of the metal M and each X represents an anionic leaving group) in a non-coordinating or weakly coordinating solvent at a temperature of about 20 ° C or higher, preferably at a temperature of from about 20 ° C to about 100 ° C, followed by reaction of the resulting mixture with an excess of alkylating agent and isolation of the resulting metal complex. In a preferred embodiment of the process, the boiling point of the solvent is above 60 ° C, such as, for example, toluene, xylene, benzene and / or hexane. In another embodiment of the process, the solvent is ether and / or dichloromethane, both of which are preferred.

Metallocene compounds with sterically bulky ligand

In one embodiment of the invention, the above-described metal compound comprising a Group 15 element can be combined with a second metal compound to form a mixed catalyst system. Said second metal compound is preferably a metallocene with a sterically bulky ligand.

9 · 9 ·

9 9 99 9

9 9 •9 9999

Generally, the sterically bulky ligand metallocene group comprises semi- and fully sandwich compounds containing one or more sterically bulky ligands that are bound to at least one metal atom. Typical sterically bulky ligand metallocene compounds are generally described as containing one or more sterically bulky ligands and one or more leaving groups attached to at least one metal atom. In a preferred embodiment, at least one of said sterically bulky ligands is η-bound to said metal atom, most preferably η⁵- to the said metal atom.

Sterically hindered ligands are generally represented by one or more open, acyclic or fused ring groups or ring systems or combinations thereof. These sterically bulky ligands, preferably said ring groups or ring systems, are usually composed of atoms of elements selected from 13 to 16. preferably, said atoms are selected from the group consisting of carbon, nitrogen, oxygen, silicon, sulfur, phosphorus, germanium, boron and aluminum, or combinations thereof.

Most preferably, said ring groups or ring systems are composed of carbon atoms, such as cyclopentadienyl or cyclopentadienyl-type ligands or other ligands whose structure has similar properties to pentadiene, cyclooctatetradienyl or an imide ligand. Said metal atom is preferably selected from the group of atoms of elements of groups 3 to 15 of the periodic table and from the group of lanthanides or actinoids. Preferably, said metal atom is a transition metal belonging to Groups 4 to 12 of the Periodic Table of the Elements, preferably belonging to Groups 4, 5, and 5, respectively.

4444 »* 4*44 • 44 4 • · 4 · • 4 · · 4 · · 4

4 «4«

6. and, more preferably, said transition metal is selected from Group 4 of the Periodic Table.

In one embodiment of the present invention, the structure of the sterically bulky ligand metallocene catalyst compound can be described by Formula III

L^ANDL^(B)MQ_n (III) where

M is a metal atom of Group 3-12 of the Periodic Table of the Elements or a group of lanthanides or actinoids. Preferably, the transition metal atom belonging to group 4, 5 or 6 of the Periodic Table of the Elements and more preferably the transition metal is selected from Group 4 of the Periodic Table of Elements, most preferably the metal is a zirconium, hafnium or titanium atom;

L^AND and L^b are sterically bulky ligands which are open, acyclic or fused ring groups or ring systems, which ligands may be any auxiliary ligand systems which include unsubstituted or substituted cyclopentadienyl or cyclopentadienyl-type ligands, heteroatom-substituted cyclopentadienyl-type ligands and / or ligands of a cyclopentadienyl type containing a heteroatom.

Examples of sterically bulky ligands include cyclopentadienyl ligands, cyclopentafenanthrenyl

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ligands, indenyl ligands, benzindenyl ligands, fluorenyl ligands, octahydrofluorenyl ligands, cyclooctatetraendiyl ligands, cyclopentacyclododecene ligands, azenyl ligands, azulene ligands, pentalene ligands, phosphoyl ligands, phosphinimine ligands (see U.S. Pat. International Publication No. WO 99/40125), pyrrolyl ligands, pyrazolyl ligands, carbazolyl ligands, borbenzene ligands and the like, including but not limited to hydrogenated versions of the above-mentioned ligands, such as tetrahydroindenyl ligands. In carrying out the present invention, the groups L may^AND and L^(B) represent any ligand structure which is capable of binding to the metal atom M by a η-bond, preferably η³-binding and most preferably g^b-binding. In another embodiment of the invention, the atomic molecular weight (MW) of the L group is^and or L^(B) greater than 60 atomic mass units (amu), preferably greater than 65 atomic mass units (amu). According to another embodiment of the present invention, the groups L can^AND and L^(B) contain one or more heteroatoms such as nitrogen, silicon, boron, germanium, sulfur and phosphorus, in combination with carbon atoms, so that these atoms together form an open, acyclic, or preferably fused, ring group or ring system such as a heterocyclopentadienyl auxiliary ligand. A group of other sterically bulky L ligands^AND and L^(B) includes, but are not limited to, sterically bulky amides, phosphides, alkoxides, aryloxides, imides, carbolides, borolides, porphyrins, phthalocyanines, corrines, and other polyazamacrocyclic groups. Independently of each other, groups L may^AND and L^(B) represent the same or different types of sterically bulky ligands that are &amp; lt; RTI ID = 0.0 &amp; gt; &amp; quot; &amp; quot; &amp; lt; / RTI &amp; gt; Ftwrt compounds • bonded to metal atom Μ. In one possible variant of formula III, only one of the groups L is present^AND and L^(B).

The groups L may be independently of one another^AND and L^(B)unsubstituted or substituted by a combination of substituent groups R. An example of a substituent group R is one or more substituents selected from the group consisting of hydrogen, linear, branched alkyl or alkenyl, alkynyl, cycloalkyl or aryl, acyl, aroyl, alkoxy, aryloxy, alkylthiol a dialkylamino group, an alkoxycarbonyl group, an aryloxycarbonyl group, a carbamoyl group, alkyl or dialkylcarbamoyl, acyloxy, acylamino, aroylamino, linear, branched or cyclic alkylene and combinations thereof, without limitation to the examples. In a preferred embodiment of the invention, the substituent groups R contain up to 50 non-hydrogen atoms, preferably from 1 to 30 carbon atoms, which may also be substituted by halogens or heteroatoms and the like. Exemplary alkyl substituents R include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl, or phenyl, and the like, including, but not limited to, any isomers thereof. such as a target. butyl, isopropyl and the like. Other hydrocarbyl groups include fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromhexyl, chlorobenzyl, and hydrocarbon-substituted organometallic groups including trimethylsilyl, trimethylgermyl, methyldiethylsilyl, and the like, and the like. halogenated hydrocarbon groups, whose group includes tris (trifluoromethyl) silyl, methylbis (difluoromethyl) silyl, bromomethyldimethylgermyl and the like, disubstituted boron-containing moieties such as dimethylboron, and disubstituted pnictide-containing moieties such as dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine containing chalkogens such as methoxy, ethoxy, propoxy, phenoxy, methylsulfide and ethylsulfide. The group of non-hydrogen substituents R includes carbon, silicon, boron, aluminum, nitrogen, phosphorus, oxygen, tin, sulfur, germanium and the like, including olefins such as olefinically unsaturated vinyl-terminated ligands such as but-3-enyl a group, a prop-2-enyl group, a hex-5-enyl group and the like, without being limited to the examples. At least two R groups, preferably two adjacent R groups, are joined to form a ring structure containing from 3 to 30 atoms selected from the group consisting of carbon, nitrogen, oxygen, phosphorus, silicon, germanium, aluminum, boron and combinations thereof. When R represents a group such as 1-butanyl, it may be bonded to the M atom by a sigma bond from a carbon atom.

Other ligands, such as at least one leaving group Q, may be bonded to the metal atom M. Depending on the oxidation state of said metal, n is 0, 1 or 2, so that the above formula (III) shows a neutral metallocene-based catalyst with a sterically bulky ligand.

Examples of ligands that Q may represent include weak bases such as amines, phosphines, ethers, carboxylates, dienes, hydrocarbon radicals containing from 1 to 20 carbon atoms, hydrides or halogens and the like, or combinations thereof, without limitation to the examples. In another embodiment of the invention, two or more Q groups form part of a fused ring or ring system. As another example of Q ligands, the above-described R substituents include cyclobutyl, cyclohexyl, heptyl, tolyl, trifluoromethyl, tetramethylene, pentamethylene, methylidene, methoxy, ethoxy, propoxy, phenoxy, bis (N-methylanilidine), dimethylamide, dimethylphosphide and the like.

In one embodiment of the present invention, a group of metallocene-based catalyst compounds with a sterically bulky ligand comprises a compound of formula III wherein L is^AND and L^(B) together via at least one bridging group A, so that the structure of these compounds can be represented by the general formula IV

L^ANDAL^(B)MQ_n (IV) • 9 · ·

The bridged structures of formula (IV) are known as metallocene-based catalyst compounds with a bridged, sterically bulky ligand. In this formula, they have L groups^AND, L^(B), M and Q have the same meaning as in general formula I. An example of a bridging group A is bridging groups containing at least one atom of the 13th to 16th group of the Periodic Table of the Elements, often referred to as bivalent groups such as at least one atom selected from the group consisting of carbon atom, oxygen atom, nitrogen atom, silicon atom, aluminum atom, boron atom, germanium and tin atom, and combinations thereof, without limitation to the examples given. Preferably the bridging group A comprises a carbon atom, a silicon atom or a germanium atom, more preferably the group A contains at least one silicon atom or at least one carbon atom. The bridging group A may also contain substituent groups R as defined above, including halogen atoms and an iron atom. Examples of bridging group A include, but are not limited to, compounds of formulas R '₂C, R '₂Si, R '₂SiR '₂Si, R '₂Ge, R'P, wherein R 'are independently selected from the group consisting of a hybrid group, a hydrocarbon group, a substituted hydrocarbon group, a halogenated hydrocarbon group, a substituted halogenated hydrocarbon group, an organometallic group substituted with a hydrocarbon group, an organometallic group substituted with a halogenated hydrocarbon group, disubstituted boron atom, disubstituted atom from the group of a substituted atom from the chalcogen group and a halogen atom or two R 'groups may be joined to form a ring or ring system.

In one embodiment of the present invention, said catalyst compounds based on bridged metallocenes include:

44· *

44 With sterically bulky ligand (IV) two or more bridging groups A (see European Patent No. EP 664 301).

In another embodiment of the invention, the sterically bulky ligand metallocene-based catalyst compounds are those wherein the R substituents are sterically bulky L ligands^AND and L^(B) in formulas III and IV substituted by the same or different number of substituents.

In another embodiment, said sterically bulky L ligands^AND and L^(B)they differ from each other in formulas III and IV.

Other sterically bulky ligand metallocene-based catalyst compounds and catalyst systems suitable for use in the present invention may include the catalyst compounds and catalyst systems disclosed in U.S. Patent Nos. 5,963,749;

<td>US</td><td> 5,064,802,</td><td>US</td><td> 5,145,819,</td><td>US</td><td>5,149,819, U.S. Pat</td><td> 5,243,</td><td> 001,</td>

<td>US</td><td> 5,239,022,</td><td>US</td><td> 5,276,208,</td><td>US</td><td>5,296,434, U.S. Pat</td><td> 5,321,</td><td> 106,</td>

<td>US</td><td> 5,329,031,</td><td>US</td><td> 5,304,614,</td><td>US</td><td>5,677,401, U.S. Pat</td><td> 5,723,</td><td> 398,</td>

<td>US</td><td> 5,753,578,</td><td>US</td><td> 5,854,363,</td><td>US</td><td>No. 5,856,547, US</td><td> 5,858,</td><td> 903,</td>

<td>US</td><td> 5,859,158,</td><td>US</td><td> 5,900,517,</td><td>US</td><td>5,939,503 and US</td><td> 5, 962</td><td> ,718</td>

International Publication Nos. WO 93/08221,

WO 93/08199, WO 95/07140, WO 98/11144, WO 98/41530, WO 41529, WO 98/46650, WO 99/02540 and WO 99/14221 and European Patent Publication Nos. 0 and 0, respectively. 578 838, EP 0 638 595, EP 0 513 380

EP 0 816 372, EP 0 839 834, EP 0 632 819, EP 0 739 361

EP 748 821 and EP 0 757 996, all of which are incorporated herein by reference.

• ♦ · ·

In another embodiment of the invention, a group of sterically bulky ligand metallocene-based catalyst compounds suitable for use in the present invention comprises a heteroatom-bridged metallocene compound comprising a single sterically bulky ligand. These types of catalysts and catalyst systems have been described, for example, in WO 92/00333,

WO 94/07928, WO 91/04257, WO 94/03506, WO 96/00244,

WO 97/15602 and WO 99/20637, U.S. Pat. Nos. 5,057,475, 5,096,867, 5,055,438,

US 5,198,401, US 5,227,440 and US 5,264,405 and European Published Patent Application EP 0 420 436, all of which are incorporated herein by reference.

According to this embodiment of the present invention, the structure of the sterically bulky ligand metallocene catalyst compound can be described by formula V

L^CAJMQ_n (V) where

M is a metal of group 3 to 16 of the Periodic Table or a metal of the group of lanthanides or actinoids. Preferably, a Group 4 to Group 12 transition metal atom, more preferably a Group 4, Group 5 or Group 6 transition metal, and even more preferably a transition metal selected from Group 4 in any oxidation state, most preferably a titanium atom;

L^C is a substituted or unsubstituted sterically bulky ligand bound to metal M;

J is a group bound to metal M and represents a heteroatom-containing auxiliary ligand;

A is a group bound simultaneously to the metal M and the group J and represents a bridging group;

Q is a monovalent anionic ligand; and n is an integer of 0, 1 or 2.

In this embodiment, the group has L^C in formula V, L is L^C, A and J condensed ring system. In this embodiment, they have L groups^AND, A, M and Q in formula V have the same meaning as in formula III.

In formula (V), J is a heteroatom-containing ligand wherein J is an element with a coordination number of 3 selected from group 15 of the Periodic Table of Elements or a group 16 element of a Periodic Group with the coordination number of 2. In a preferred an embodiment of the group J contains a nitrogen atom, a phosphorus atom, an oxygen atom or a sulfur atom, most preferably it contains a nitrogen atom.

According to another embodiment of the invention, said sterically bulky ligand metallocene catalyst compounds may be heterocyclic ligand complexes in which the sterically bulky ligands, which are formed by one or more rings or ring systems, contain one or more heteroatoms or a combination thereof . Examples of suitable heteroatoms include elements from 13 to 16. groups of the Periodic Table of the Elements, preferably nitrogen, boron, sulfur, oxygen, aluminum, silicon, phosphorus, and tin, without being limited to the examples given. Specific examples of such sterically bulky ligand metallocene catalyst compounds have been described in International Publication Nos. WO 96/33202, WO 96/34021, WO 97/17379, WO 98/22486, European Patent Application EP 0 874 005 and U.S. Patent Nos. 5,637,660, 5,539,124,

US 5,554,775, US 5,756,611, US 5,233,049, US 5,744,417 and US 5,856,258, the contents of which are incorporated herein by reference.

In another embodiment of the present invention, said sterically bulky ligand metallocene catalyst compounds may be complexes known as transition metal catalysts and bidentate pyridines containing pyridine or quinoline groups, such as those described in U.S. Patent Application No. USSN No. 09 / 103,620, filed June 23, 1998, the contents of which are incorporated herein by reference. In another embodiment of the present invention, said sterically bulky ligand metallocene catalyst compounds are the complexes disclosed in International Publication Nos. WO 99/01481 and WO 98/42664, the contents of which are incorporated herein by reference.

According to another embodiment of the invention, said metallocene-based catalyst with a sterically bulky ligand may be a metal complex, preferably a transition metal, a sterically bulky ligand, preferably a substituted or unsubstituted π-linked ligand, and one or more heteroallyl groups such as those described in patents US 5,527,752 and US 5,747,406, and in European patent EP 0 735 057, the contents of which are incorporated herein by reference.

It is also contemplated that any of the bulky ligand metallocene-based catalyst compounds of the present invention comprises at least one fluoride or fluorine-containing leaving group as described in U.S. Patent Application Ser.

USSN 09 / 191,916, filed Nov. 13, 1998.

In another embodiment, the other metal compound or the second metal compound of the present invention is a sterically bulky ligand metallocene catalyst compound of the formula VI.

L^DMQ₂(YZ) X_n (VI) where

M is a Group 3 to Group 16 metal atom, preferably a Group 4 to Group 12 transition metal atom, more preferably a Group 4, 5 or 6 transition metal group;

L^d a sterically bulky metal-bound ligand M; and this ·· • to «· ♦ it

Q are all independently bonded to metal M;

Q₂(YZ) forms a single-charge polydentate ligand;

A or Q represents a monovalent anionic ligand which is also bound to the metal M;

X is a monovalent anionic group when n is equal to or a divalent anionic group when n is equal to 1;

n is 1 or 2.

In formula VI, groups L and M have the same meaning as similar groups in formula III. The group Q has the same meaning as a similar group in formula III, preferably the group Q is selected from the group consisting of -O-, -NR-, —CR₂- and -S-; Y represents either a carbon atom or a sulfur atom; Z is selected from the group consisting of -OR, -NR₂, -CR₃, -SR, -SiR₃, -PR group₂, hydrogen and substituted or unsubstituted aryl, provided that when Q is -NR-, then Z is selected from the group consisting of -OR, -NR₂, -SR, -SiR₃, -PR group₂ and hydrogen; R is selected from the group consisting of carbon, silicon, nitrogen, oxygen and / or phosphorus, with R being preferably a hydrocarbon group containing from 1 to 20 carbon atoms, more preferably an alkyl group, a cycloalkyl group or an aryl group; n is an integer from 1 to 4, preferably 1 or 2; X is a monovalent anionic group when n is 2 f · ♦ «

I »

or X is a divalent anionic group when n is 1; preferably X represents a carbamate group, a carboxylate group or another heteroallyl group described by a combination of Q, Y and Z groups.

In a particularly preferred embodiment of the present invention, the sterically bulky ligand metallocene compound is a compound of the formula:

<img file="CZ20021402A3_D0007.tif" />

CH₃

In the mixed catalyst system of the present invention, the above-described first and second metal compounds are mixed together in a molar ratio of from 1: 1000 to 1000: 1, preferably from 1:99 to 99: 1, more preferably from 10:90 to 90:10 even more preferably in a ratio from 20:80 to 80:20, more preferably in a ratio from 30:70 to 70:30 and most preferably in a ratio from 40:60 to 60:40. In particular, the selected ratio of the individual compounds depends on the desired properties of the end product and / or the mode of activation.

Activating agent and methods of activation

The metal compounds described above are usually activated in various ways to form a catalyst compound containing an empty compound.

<img file="CZ20021402A3_D0008.tif" />

Also a coordination site at which one or more olefins are coordinated, inserted and polymerized.

For the purposes of the present invention, the term "activator" or "activating agent" means any compound or component or method by which any of the above-described metal compounds containing an atom of a Group 15 element and / or said metallocene-based catalyst compound sterically activated bulky ligand. Examples of activating agents include Lewis acid or a non-coordinating ionic activator or ionizing activator, or any other compound which includes Lewis bases, alkylaluminum, commonly used types of cocatalysts, and combinations thereof capable of converting a neutral metallocene catalyst compound to sterically a bulky ligand or metal compound containing the element of 15. a group of the Periodic Table of the Elements into a catalytically active metal compound containing an element of the 15th group of the Periodic Table of Elements, respectively, to a catalytically active metathiocene cation with a sterically bulky ligand. The present invention also includes the use of an alumoxane or modified alumoxane as an activating agent and / or the use of ionizing activating agents, either neutral or ionic, such as tri (n-butyl) ammonium tetrakis (pentafluorophenyl) boron, trisperfluorophenyl boron organometallic precursor, or trisperfluoronaphthyll polyhalogenated heteroborane anions (see. International Publication No. WO 98/43983) or combinations thereof which are capable of ionizing a neutral metallocene-based catalyst with a sterically bulky ligand and / or catalytic

0 « 0

0« ♦ 00 · • •00

0 « 0 0 0

0 0.0404 a metal compound comprising an element of a Group 15 element of the Periodic Table of the present invention.

In one embodiment of the present invention, an activation method can be used in which ionic compounds without active proton are used but which are capable of producing both a catalytic cation of a Group 15 element or a sterically bulky metallocene catalytic cation ligand, such a non-coordinating anion. Such compounds have been described in published European patent applications EP 0 426 637, EP 0 573 403 and US 5,387,568, the contents of which are incorporated herein by reference.

There are many processes for the preparation of alumoxane and modified alumoxanes, and a specific example of such a process is disclosed in U.S. Patent Nos. 4,665,208, 4,952,540, 5,091,352,

US 5,206,199, US 5,204,419, US 4,874,734, US 4,924,018,

US 4,908,463, US 4,968,827, US 5,308,815, US 5,329,032,

US 5,248,801, US 5,235,081, US 5,157,137, US 5,103,031,

US 5,391,793, US 5,391,529, US 5,693,838, US 5,731,253,

US 5,731,451, US 5,744,656, US 5,847,177, US 5,854,166,

US 5,856,256 and US 5,939,346 and European Published Patent Applications EP 0 561 476, EP 0 594 218, European Patent Nos. EP 0 279 586 and EP 0 586 665 and International Publication Number WO 94/10180, without limitation to said examples, the contents of all the above-mentioned documents being incorporated herein by reference.

ti · »·· ·· ···· titi ·« ·· ti ·· ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ti ··· titi ti ti ·····

The organoaluminum compounds used as activating agents of the present invention include trimethyl aluminum, triethyl aluminum, triisobutyl aluminum, tri-n-hexyl aluminum, tri-n-octyl aluminum, and the like.

The ionizing compounds may contain active hydrogen, or any other cation that is associated but not coordinated or only weakly coordinated with the remaining ion of said ionizing compound. Such compounds and the like have been described in published European patent applications EP 0 570 982, EP 0 520 732, EP 0 495 375, EP 0 277 003 and EP 0 277 004, in European Patent No. EP 0 500 944, in U.S. Pat. US states 5,153,157

US 5,198,401, US 5,066,741, US 5,206,197, US 5,241,025,

US 5,384,299 and US 5,502,124, and U.S. Patent Application Ser. No. 08 / 285,380, filed Aug. 3, 1994, the contents of all of the above cited documents being incorporated herein by reference.

Other activating agents include those described in International Publication Number WO 98/07515, the contents of which are incorporated herein by reference, exemplified by tris (2,2 ', 2' '- nonafluorobiphenyl) fluoroaluminate. The present invention also encompasses the use of mixtures of activating agents, such as mixtures of alumoxanes and ionizing activating agents, as described, for example, in European Patent No. EP 0 573 120, in published International Applications Nos. WO 94/07928 and WO 95/14044, and in United States patents. US Nos. 5,153,157 and 5,453,410, with the contents of

<img file="CZ20021402A3_D0009.tif" />

all of these documents are incorporated herein by reference. WO 98/09996, the disclosure of which is incorporated herein by reference, describes the activation of catalyst compounds by perchlorates, periodinates, including hydrates thereof. WO 98/30602 and WO 98/30603, the contents of which are incorporated herein by reference, have described the use of a lithium (2,2'-bisphenylditrimethylsilicate) solvate with 4 molecules of THF as the catalyst compound activator. WO 98/18135, the contents of which are incorporated herein by reference, discloses the use of organoboron-aluminum activating agents. EP 0 781 299 describes the use of a silylium salt in combination with a non-coordinating compatible anion. Other methods of activation, such as the use of radiation, can also be used to convert a neutral catalyst compound or precursor into a catalytic cation by which olefins can be polymerized (cf. EP 0 615 981, the contents of which are incorporated herein by reference) ), electrochemical oxidation, etc. Other activating agents or methods for activating catalytic compounds have been described, for example, in U.S. Patent Nos. 5,849,852, 5,859,653 and 5,869,723, and in International Publication Nos. WO 98/32775 and WO 99/42467 (dioctadecylmethylammoniumbis (tris (pentafluorophenyl) borane) benzimidazole) ), the contents of which are incorporated herein by reference.

In one embodiment of the invention, said activating agent is a Lewis acid, more preferably a Lewis acid. 9 · 99 99 9999 99 99

9 99 9 9999 • 9 999 99 9 • 9 9999 999 9

999 999

9999 99 9 99 9999 aluminum-based acid, more preferably neutral aluminum-based Lewis acid, comprising at least one, preferably two, halogenated aryl ligands and one or two other monoanionic ligands, which are not halogenated aryl ligands. The group of Lewis acids used in this embodiment includes aluminum-based Lewis acids that contain at least one sterically bulky, electron-acceptor helper ligand, such as a halogenated aryl ligand contained in tris (perfluorophenyl) borane or tris (perfluoraphthyl) borane. The sterically bulky auxiliary ligands are those which are sufficient for the Lewis acids to function as electronically stabilizing, compatible, non-coordinating anions. The formation of stable ionic complexes occurs when said anions are not suitable ligands for strong Lewis acids, which in this case are transition metal cations containing a group 15 element of the Periodic Table of Elements used in the advertising polymerization, i. if the transfer of the ligand is avoided, which would lead to the neutralization of said cations and thus their deactivation due to the ongoing polymerization.

The Lewis acids meeting the above description of the preferred activating agent of the present invention can be described by Formula VII

R_nAl (ArHal) 3-n (VII) where is the monoanionic ligand 44 4944 44 49

9 4 9 4 4 4 4 4 • · «·· ·· · « · · · · · » 9

4 4 44 4 444944

ArHal is a halogenated aromatic group having 6 carbon atoms or a polycyclic aromatic group having a higher number of carbon atoms or a group containing aromatic rings in which two or more rings (or fused ring systems) are bonded directly to each other; and n is 1 to 2, preferably 1.

In another embodiment, at least one group (ArHa1) in formula VII is a halogenated aromatic group containing at least 9 carbon atoms, preferably a fluorinated naphthyl group. Suitable R ligands include a substituted or unsubstituted aliphatic or aromatic hydrocarbon group containing from 1 to 20 carbon atoms, and substituted means that at least one hydrogen bonded to the carbon atom of the group is replaced by a hydrocarbon group, halide, halogenated hydrocarbon group or organometallic a hydrocarbon or halogenated hydrocarbon group, a dialkylamido group, an alkoxy group, siloxyl, aryloxy, alkylsulfido, arylsulfido, alkylphosphido or another anionic substituent; fluoride; sterically bulky alkoxides, the term sterically bulky in this context means a hydrocarbon group containing at least 4 carbon atoms, for example up to 20 carbon atoms, such as a tert. butoxide group, 2, β-dimethylphenoxide, 2, β-di (tert-butyl) phenoxide; -SR, -NR₂, -PR group₂wherein R is independently selected from the group consisting of substituted or unsubstituted hydrocarbon as defined above; and the organometallic group frfr fr • frfrfr

<img file="CZ20021402A3_D0010.tif" />

fr fr

<img file="CZ20021402A3_D0011.tif" />

Containing a hydrocarbon group containing from 1 to 30 carbon atoms, such as a trimethylsilyl group, without being limited thereto.

Specific examples of the group ArHal include phenyl, naphthyl and anthracenyl according to U.S. Patent No. 5,198,401 and halogenated biphenyl groups according to WO 97/29845. For the purposes of this invention, halogenated or halogenated is understood to mean that at least one third of the hydrogen atoms bound to the carbon atoms that form the aryl-substituted aromatic ligands are replaced by halogen atoms, and it is more preferred that said aromatic ligands are perhalogenated. The most preferred halogen of the present invention is fluorine.

According to another embodiment of the present invention, the molar ratio of the metal of the activator component to the metal component of the catalytic metal compound comprising a Group 15 element supported on a suitable support is in the range of 0.3: 1 to 1000: 1, preferably a range of from 20: 1 to 800: 1, and more preferably a range of from 50: 1 to 500: 1. When the activating agent is an ionizing activator, such as tetrakis (pentafluorophenyl) boron anionic activators, the molar ratio of metal in the activator component to the metal component of the catalyst compound hafnium group 15 is from 0.3: 1 to 3 : l.

In a further embodiment of the invention, the above-described metal catalyst compounds comprising an atom of the element of zinc are possible. · »»

15 Dec groups of the Periodic Table of the Elements and / or the above-described sterically bulky ligand metallocene catalyst compounds with one or more catalyst compounds of formulas (III) to (VI) and one or more activators or activation methods described above.

In another method of forming the mixed catalyst composition of the present invention, the modified alumoxanes are mixed with the first and second metal compounds of the present invention to form a catalyst system. In another embodiment, MMAO3A (which is a modified methylalumoxane in heptane, commercially available from Akzo Chemicals, Inc.) is blended. The Netherlands under the trade name Modified Methylalumoxan type 3A, cf. for example, examples of such aluminoxanes described in U.S. Patent No. 5,041,584, the contents of which are incorporated herein by reference) with said first and second metal compounds to form a catalyst system.

In a particular embodiment of the present invention, when using metal compounds of formulas 1 and 2, which are both activated by the same activating agent, the preferred content of each compound, expressed as a percentage by weight based on the total weight of both said compounds, 10 to weight percent of the compound of formula 1 and from 5 to 90 weight percent of the compound of formula 2, preferably from 50 to 90 weight percent of the compound of formula 1 and from 10 to 50 weight percent of the compound of formula 2, more preferably from 60 to 80 weight percent of the compound of formula 1 and from 40 to 20 weight percent of the compound of formula 2. activates

<img file="CZ20021402A3_D0012.tif" />

with methylalumoxane, into the reactor.

mixed with the compound of formula 2 and injected

In another particular embodiment of the present invention, when a compound of formula I and an indenyl zirconium trispivalate are used, both of which are activated with the same activating agent, the content of each compound, expressed as a percentage by weight based on the total weight of both catalysts, is preferred. carriers, from 10 to 95% by weight of the compound of formula (I) and from 5 to 90% by weight, preferably from 50 to 90 weight percent of the compound of formula I and from 10 to weight percent of the indenyl zirconium trispivalate, more preferably from 60 to 80 weight percent of the compound of the formula I and from 40 to 20 weight percent of the indenyl zirconium trispivalate. In a particularly preferred embodiment, the indenyl zirconium trispivalate is activated with methylalumoxane, mixed with the compound of formula I and injected into the reactor.

Generally, the metal compounds of the present invention are mixed with the activating agent in ratios of from about 1000: 1 to about 0.5: 1. Preferably, the metal compounds of the present invention are mixed with the activating agent in a ratio of from about 300: 1 to about 1: 1, preferably from about 150: 1 to about 1: 1, when borates, borates, aluminates, etc. are used. preferably said ratio is from about 1: 1 to about 10: 1, and when using alkyl aluminum compounds (such as diethylaluminum chloride in admixture with water), said ratio is preferably from about 0.5: 1 to about 10: 1.

• · • · · ·

Conventional catalyst systems

The mixed catalyst composition of the present invention may optionally include a metal compound as described above comprising a Group 15 element and a conventional transition metal catalyst.

Conventional transition metal catalysts include Ziegler-Natta catalysts, vanadium catalysts, and Phillips catalysts, which are well known to those skilled in the art. Examples of Ziegler-Natta catalysts have been described in Ziegler-Natta Catalysts and Polymerizations, John Boor, Academic Press, New York,

1979. Examples of conventional transition metal catalysts are also discussed in U.S. Patent Nos. 4,115,639, 4,077,904, 4,482,687, U.S. Pat.

US 4,564,605, US 4,721,763, US 4,879,359, US 4,960,741, the contents of which are incorporated herein by reference. Conventional transition metal catalyst compounds which can be used according to the present invention comprise transition metals from Group 3 to 17 of the Periodic Table of the Elements, preferably from Groups 4 to 12 of the Periodic Table, more preferably from Groups 4 to 6 of the Periodic Table. system elements.

The structure of these conventional transition metal catalysts can be represented by the general formula

MR_X where

M is a metal atom of Group 3-17, preferably Group 4-6, more preferably Group 4, most preferably titanium;

R is a halogen atom or an oxycarbon group; and x is the oxidation state of metal M.

Specific examples of R include, but are not limited to, alkoxy, phenoxy, bromide, chloride, and fluoride. A specific example of a conventional transition metal catalyst in which M is titanium is TiCl₄, TiBr₄Ti (OC₂H₅) ₃C1, Ti (OC₂H₅) Cl₃Those (OC₄H₉)₃C1, Ti (OC₃H₇)₂NO. 1₂Ti (OC₂H₅)₂Br₂,

TiCl₃.1 / 3A1C1₃ and Ti (OC12H25) Cl₃, without being limited to these examples.

Conventional transition metal catalyst compounds based on electron donor magnesium / titanium complexes that can be used in the present invention have been described, for example, in U.S. Patent Nos. 4,302,565 and 4,302,566, the contents of which are incorporated herein by reference. It is particularly preferably used

MgTiCl₆(ethyl acetate) 4.

GB 2,105,355 and US 5,317,036, the contents of which are incorporated herein by reference, disclose various conventional vanadium catalyst compounds. Examples of a conventional catalytic vanadium compound include vanadyl trihalide, vanadylalkoxy halides, and vanadyl alkoxy halides and &amp; lt; RTI ID = 0.0 &amp; gt; J &amp; lt; / RTI &amp; gt; Vanadylalkoxides such as VOCl 3, VOCl 2 (0Bu), where Bu is a butyl group, and VO (OC)₂H₅)₃; vanadium tetrachloride and vanadium alkoxy halides such as VCI4 and VC1₃(0Bu), vanadium and vanadylacetoacetonates and chloroacetylacetonates such as V (AcAc) 3 and VOC1₂ (AcAc), wherein (AcAc) is an acetylacetonate group, without being limited to these examples. A group of preferred conventional vanadium catalyst compounds include VOCl 3, VCl 4 and VOC 1₂-OR, where R is a hydrocarbon radical, preferably an aliphatic or aromatic hydrocarbon radical containing from 1 to 10 carbon atoms such as ethyl, phenyl, isopropyl, butyl, propyl, n-butyl, isobutyl, tert. butyl, hexyl, cyclohexyl, naphthyl, etc., and vanadium acetoacetonates.

A group of conventional catalytic chromium compounds, often referred to as Phillips catalysts suitable for use in the present invention, include CrO₃, chromocene, silyl chromate, chromyl chloride (CrO₂Cl₂), chromium-2-ethylhexanoate, chromacetylacetonate (Cr (AcAc)₃) etc.

Non-limiting examples of such catalysts are described in U.S. Patent Nos. 3,709,853,

US 3,709,954, US 3,231,550, US 3,242,099 and US 4,077,904, the contents of which are incorporated herein by reference.

Other conventional transition metal catalyst compounds and catalyst systems suitable for use in the present invention have been described in U.S. Patent Nos. 4,124,532, 4,302,565, 4,302,566, U.S. Pat.

US 4,376,062, US 4,379,758, US 5,066,737, US 5,763,723,

US 5,849,655, US 5,852,144, US 5,854,164 and US 5,869,585 and European Published Patent Application Nos.

EP 0 416 815 and EP 0 420 436, the contents of which are incorporated herein by reference.

Other catalysts may include cationic catalysts such as AlCl₃ and other well known cobalt, iron, nickel and palladium catalysts. See. for example, U.S. Pat. Nos. 3,487,112, 4,472,559,

US 4,182,814 and US 4,689,437, the contents of which are incorporated herein by reference.

Typically, these conventional transition metal catalyst compounds, with the exception of some conventional chromium catalyst compounds, are activated by one or more of the conventional cocatalysts described below. Conventional transition metal catalysts can also be activated by the above activating agents, as will be apparent to those skilled in the art.

The structure of conventional cocatalysts for use in conjunction with the conventional transition metal catalyst compounds described above may be described by the general formula:

M³M⁴vX²cR³b._C where

M³ is a metal atom of Groups 1 to 3 and 12 to 13 of the Periodic Table of the Elements;

M⁴ is a Group 1 metal atom;

<img file="CZ20021402A3_D0013.tif" />

v is a number from 0 to 1;

X² is halogen;

c is a number from 0 to 3;

R³ a monovalent hydrocarbon radical or a hydrogen atom;

b is a number from 1 to 4, wherein the difference bc is at least equal to

1.

The structure of other conventional organometallic cocatalysts for use together with the conventional transition metal catalyst compounds described above may be described by the general formula:

M³R³to where

M³ is a metal of IA, IIA, IIB or IIIA of the Periodic Table of the elements such as lithium, sodium, beryllium, barium, boron, aluminum, zinc, cadmium and gallium;

k is equal to 1, 2 or 3, according to the valence of the metal M³, which itself is dependent on the particular group to which the metal M belongs³;

R³ it may be a monovalent hydrocarbon residue.

Examples of conventional organometallic cocatalysts for use in conjunction with the conventional catalyst compounds described above include methyl lithium, butyllithium, dihexyl mercury, butyl magnesium, diethylcadmium, benzyl potassium, diethylzinc, tri-n-butyl aluminum, diisobutylethyl boron, diisobutylethyl boron, diethylkutylethyl boron, diethylcadlethyl boron and tri-n-amylbore, especially alkyl aluminum such as, but not limited to, trihexyl aluminum, triethyl aluminum, trimethyl aluminum and triisobutyl aluminum. Other conventional cocatalysts include Group 2 monoorganohalides and hydrides of Group 2 and Group 3 and 13 metal mono- or diorganohalides and hydrides. Specific examples of this type of conventional cocatalyst include diisobutylaluminium bromide, isobutylboronium dichloride, methylmagnesium chloride, ethylberyllium chloride, ethylcalcium aluminum hydride, methylcadmium hydride, diethylboronium hydride, hexylberyl borohydride, dicropyl borohydride, dipropyl borohydride, dibasyl borohydride, di-isobutyl borohydride. Conventional organometallic cocatalytic compounds are well known to those skilled in the art and are discussed in more detail in U.S. Patent Nos. 3,221,002 and 5,093,415, the contents of which are incorporated herein by reference.

Carriers and general application methods

The above-described catalyst compound comprising a Group 15 element and a mixed catalyst system of the present invention comprising a catalyst compound comprising a Group 15 element and a sterically bulky ligand metallocene catalyst, or a conventional catalyst compound, is a catalyst compound. possible • · ·

<img file="CZ20021402A3_D0014.tif" />

combined with one or more support materials or carriers using coating methods well known in the art of catalyst manufacture and described below. For example, in one embodiment of the present invention, a catalyst compound comprising the element of 15. or a mixed catalyst system of the present invention together with a suitable carrier, wherein the catalyst compound or mixed catalyst system can be deposited, contacted, steamed (i.e. in the form of vapors), it may be bound to, incorporated into, or adsorbed to, or absorbed into or onto the carrier. Also encompassed by the present invention is the use of a mixed metal system wherein said sterically bulky ligand metallocene catalyst is supported on a carrier other than a compound containing a Group 15 element. This arrangement is used especially in the case of polymerization in several reactors, where one reactor uses a supported catalyst system for the production of a high molecular component and another catalyst uses a second catalyst system for the production of a low molecular component. on a suitable carrier.

The terms "carrier material" or "carrier" are used interchangeably to mean any carrier material, preferably a porous carrier material, including inorganic and organic carrier materials. Examples of inorganic carrier materials are inorganic oxides and inorganic chlorides. Other carriers include polymeric carrier materials such as polystyrene, functionalized or crosslinked organic carrier materials such as polystyrene-divinylbenzene polyolefins, polymeric compounds or any other organic or inorganic carrier material and the like, and mixtures thereof, without limitation to these examples. .

Preferred carriers are inorganic oxides, the group of which comprises the oxides of metals of Groups 2, 3, 4, 5, 13 and 14 of the Periodic Table of the Elements. Preferred carriers include silica, alumina, alumina and mixtures thereof. Other carriers useful in the present invention include magnesium oxide, titanium dioxide, zirconium oxide, magnesium chloride, montmorillonite (see European Patent No. EP 0 511 665), phyllosilicate, zeolites, talc, clays and the like. It is furthermore possible according to the invention to use mixtures of said carrier materials, such as silica containing chromium, alumina-silica, silica-titanium dioxide and the like. Other carrier materials can be, for example, the porous acrylate polymers described in EP 0 767 184, the contents of which are incorporated herein by reference.

According to the present invention, it is preferred that the support, most preferably the inorganic oxide, has a specific surface area in the range of about 10 m²/ gram to approximately 100 m²/ gram, pore volume ranging from about 0.1 cm³/ gram up to about 4.0 cm³/ gram and a mean particle size ranging from about 5 microns to about 500 microns. More preferably, the specific surface area of ​​the carrier of the present invention is in the range of about 50 m²/ gram up to approximately 500 m²/ gram, the pore volume of the support is in the range of about 0.5 cm³per gram to about 3.5 cm³/ gram and medium • 4 »·

<img file="CZ20021402A3_D0015.tif" />

the particle size of the carrier is in the range of about 10 microns to about 200 microns. Even more preferably, the specific surface area of ​​the carrier of the present invention is in the range of about 100 m²/ gram up to approximately 400 m²/ gram, the pore volume of the support is in the range of about 0.8 cm³/ gram to about 5.0 cm³and the mean particle size of the carrier is in the range of about 5 microns to about

100 ALIGN! micrometers. The mean pore size of the carrier of the invention is usually in the range of about 10 angstroms to about 1000 angstroms, preferably from about 50 angstroms to about 500 angstroms, and even more preferably from about 75 angstroms to about 450 angstroms.

Examples of supported catalyst methods for use in the present invention are described in U.S. Patent Nos. 4,701,432;

<td>US</td><td> 4,808,561,</td><td>US</td><td> 4,912,075,</td><td>US</td><td> 4,925,821,</td><td>US</td><td> 4,937,217,</td>

<td>US</td><td> 5,008,228,</td><td>US</td><td> 5,238,892,</td><td>US</td><td> 5,240,894,</td><td>US</td><td> 5,332,706,</td>

<td>US</td><td> 5,346,925,</td><td>US</td><td> 5,422,325,</td><td>US</td><td> 5,466, 649,</td><td>US</td><td> 5,466, 766,</td>

<td>US</td><td> 5,'468,702,</td><td>US</td><td> 5,529,965,</td><td>US</td><td> 5,554,704,</td><td>US</td><td> 5,629,253,</td>

<td>US</td><td> 5,639,835,</td><td>US</td><td> 5,625,015,</td><td>US</td><td> 5,643,847,</td><td>US</td><td> 5,665,665,</td>

<td>US</td><td> 5,698,487,</td><td>US</td><td> 5,714,424,</td><td>US</td><td> 5,723,400,</td><td>US</td><td> 5,723,402,</td>

<td>US</td><td> 5,731,261,</td><td>US</td><td> 5,759,940,</td><td>US</td><td> 5,767,032,</td><td>US</td><td> 5,770,664,</td>

US 5,846,895 and US 5,939,348 and US Patent Application Nos. USSN 271,598, filed July 7, 1994, and USSN 788,736, filed January 23, 1997, in International Publication Nos. WO 95/32995,

WO 95/14044, WO 96/06187 and WO 97/02297 and European Patent No. EP 0 685 494, the contents of which are incorporated herein by reference.

Many other methods are known which can be used to apply the polymerization catalysts or mixed catalyst systems of the present invention to a suitable support.

For example, hafnium compounds comprising a Group 15 element and / or a mixed catalyst system of the present invention that includes sterically bulky ligand metallocene catalyst compounds may contain a polymer-bound ligand as described in U.S. Patents Nos. 5,473,202 and 5,770,755, the contents of which are incorporated herein by reference; hafnium compounds containing the element of 15. the sterically bulky ligand metallocene based catalyst groups and / or catalyst compounds of the present invention can be spray dried as described in U.S. Patent No. 5,648,310, the contents of which are incorporated herein by reference; carrier material to be used with hafnium compounds containing the element of 15. the steric bulky ligand metallocene-based group of elements and / or catalyst compounds of the present invention may be functionalized as described in published European patent application EP 0 802 203, the contents of which are incorporated herein by reference, or at least one substituent or leaving group is selected from those described in U.S. Patent No. 5,688,880, the contents of which are incorporated herein by reference.

In a further embodiment, the present invention relates to a catalyst system comprising a compound comprising a Group 15 element and / or a mixed catalyst.

<img file="CZ20021402A3_D0016.tif" />

a system comprising sterically bulky ligand metallocene-based catalyst compounds comprising surface modifying agents used in the production of a supported catalyst system according to WO 96/11960, the contents of which are incorporated herein by reference material. The catalyst systems of the present invention can be prepared in the presence of olefins such as 1-hexene.

In another embodiment, the catalyst system comprising a hafnium compound comprising an element of 15. and a mixed catalyst system comprising a sterically bulky ligand metallocene catalyst compound of the present invention combined with a metal-containing carboxylic acid salt such as aluminum carboxylates such as aluminum mono-, di- and tristearate, octoates aluminum, aluminum oleate and aluminum cyclohexylbutyrates, as described in U.S. Patent Application Serial No. 09 / 113,213, filed July 10, 1998.

A method for applying a compound-based catalyst system comprising a Group 15 element and / or a mixed-metallocene-based sterically ligand metallocene catalyst system is described below and has also been described in U.S. Patent Application Serial Nos. USSN 265,533, filed Apr. 24, 1999. filed Jun. 24, 1994, U.S. Pat. and International Publication Nos. WO 96/00245 and WO 96/00243, the contents of which are incorporated herein by reference. In this method, a compound containing a Group 15 element is used.

<img file="CZ20021402A3_D0017.tif" />

of the Periodic Table of the Elements, either alone or together with a sterically bulky ligand metallocene-based catalyst compound. In this method, said catalyst compound or mixture of said catalyst compounds is suspended in a liquid to form a solution, and a solution containing the activating agent and the liquid is prepared in a separate vessel. The liquid may be any compatible solvent or any other liquid that is capable of forming a solution or the like form of the catalyst compound or mixture of catalyst compounds and / or activator of the present invention. Most preferably, the liquid is a cyclic aliphatic or aromatic hydrocarbon, most preferably toluene. Said solutions of the catalyst compound or mixture of catalyst compounds and activator are mixed together and added to the porous support material in such a ratio that the total volume of the solution of catalyst compound or mixture of catalyst compounds and activator solution is less than four times the pore volume of the porous support material. a volume of less than three times the pore volume of the porous support material, more preferably, the volume is less than twice the pore volume of the porous support material; the preferred range for the ratio of these volumes being in the range of 1.1 to 3.5 times, and more preferably in the range of 1.2 to 3 times.

Methods for measuring the total pore volume of a porous material are well known. Details of these methods are discussed in Experimental Methods in Catalytic Research,

Volume I, Academic Press 1968 (specifically on pages 67 to 96). These preferred methods include the use of a conventional BET device for measuring nitrogen absorption. Another well known method was described in Innes, &amp; quot; Total Porosity and Particle Density of Fluid Catalysts, &amp; quot; Liquid Titration, Analytical Chemistry, 1956, 28, 332-334.

Other methods for applying the catalyst compounds of the present invention to a support material have been described in U.S. Patent Application Ser. No. 09 / 312,878, filed May 17, 1999, the contents of which are incorporated herein by reference.

When used in a mixed catalyst system, the catalyst compound comprising a Group 15 element of the present invention and the metallocene-based catalyst compound is mixed with a sterically bulky ligand in a molar ratio of from 1: 1000 to 1000: 1, preferably from 1:99 to 99: 1, more preferably from 10:90 to 90:10, even more preferably from 20:80 to 80:20, more preferably from 30:70 to 70:30 and most preferably from 40:60 to 60:40.

In one embodiment of the blend system of the present invention, particularly when used in suspension polymerization, the total deposit amount of the compound containing the element is 15. and a sterically bulky ligand metallocene-based catalyst compound, expressed in micromoles / gram of the supported catalyst (supported catalyst, catalyst mixture and activator), about 40 micromoles / gram, preferably about 38 micromoles / gram.

99 99 9 9 9

9· · • · · • « ” · · 9 9 · · ··· · &gt;· · ·· ····

In another embodiment of the invention, in particular in the gas phase polymerization using the blend system of the present invention, the total amount of compound containing the element is 15. a Periodic Ligand Metallocene-based Catalyst Group catalyst compound expressed in micromoles / gram of the supported catalyst (supported catalyst, catalyst mixture and activator), less than 30 micromoles / gram, preferably less than 25 micromoles / gram, more preferably less than 20 micromoles / gram.

According to another embodiment of the invention, the R group of formula VII, or the ligand contained therein, may be covalently bonded to a support material, which is preferably a metal oxide or metalloid or polymer. Lewis-based carrier materials react with Lewis acid activators to attach the Lewis acid to the carrier, or to deploy the activating agent to the carrier, wherein one R group of formula R_nAl₃__n is covalently bonded to said carrier material. For example, when the support material is silica, the Lewis base is the hydroxyl groups contained in the silica, and in this method of deposition of the activating agent, it is the hydroxyl groups that bind to one coordination site of the aluminum complex. In this embodiment, the support material is preferably a metal oxide or metalloid, preferably a support material that contains hydroxyl groups on the surface of which pK is used_and is equal to or less than pK_and Amorphous silica, i.e. pK_and of these hydroxyl groups is equal to or less than about 11.

Without being limited to any theory, it is believed that a covalently bound activating agent, which is a Lewis acid, first forms a datative complex with a silanol moiety contained, for example, in silica (acting as a Lewis acid), thereby forming a formal dipolar (zwitterionic) Bronsted acid that is bound to the metal / metalloid contained in the oxide that forms the support material. Then, the proton contained in said Bronsted acid is likely to proton the R group contained in the Lewis acid, thereby cleaving it and covalently attaching the Lewis acid to the oxygen atom. Thus, the R group of the Lewis acid becomes an R'-O- group in which R 'is a suitable support material or substrate, for example silica or a polymer support containing hydroxyl groups. Any support material which contains hydroxyl groups on its surface is suitable for use in this particular method of applying catalyst to a support. Glass beads also belong to the group of these carrier materials.

In this embodiment, wherein the carrier material is a metal oxide composition, the compositions may further comprise oxides of other metals, such as oxides of aluminum, potassium, magnesium, sodium, silicon, titanium, and zirconium, the compositions preferably being thermally and / or or chemically treated to be free of water and free oxygen. Such treatment is usually carried out under vacuum in a heated furnace, in a heated fluidized bed, or with dehydrating agents such as organosilanes, siloxanes, frfrfr fr frfrfr frfrfr frfrfr frfrfr frfr frfr A fr * alkyl aluminum compound etc. The rate of treatment should be such that most of the retained moisture and free oxygen are removed as far as possible, while maintaining a chemically significant amount of hydroxyl functional groups. Thus, for example, the support material can be annealed at temperatures of up to 800 ° C or even higher if not decomposed, and if a larger amount of anionic activating agent is to be applied to the support, it is convenient to anneal the support material for a shorter period of time. If the metal oxide is silicon dioxide, it is usually convenient to apply from less than 0.1 millimole to 3.0 millimoles of activator / gram SiO onto the support.₂This can be achieved, for example, by varying the annealing temperature of the silica in the range from 200 ° C to 800 ° C. See. Zhuralev et al., Langmuir, 1987, 3, 316, which describes the correlation between annealing temperature, annealing time, and hydroxyl group content on the surface of silica particles.

The treatment of the hydroxyl groups available as binding sites can also be carried out by pretreatment prior to the addition of the Lewis acid, with less than stoichiometric amounts of chemical dehydrating agents. These reagents are used in small amounts and each contain one ligand capable of reacting with silanol groups (such as (CH).₃)₃SiCl), or which is hydrolysable in another manner, thereby minimizing interference with the reaction between the transition metal catalyst compound of the present invention and the bound activating agent. If the annealing temperature is less than 400 ° C, difunctional addition agents (such as (CH₃), Which serves to disconnect pairs of silanol groups • · · · ·

oo »··· :: · ::.

hydrogen bonded bridges that are present on the silica surface when annealing occurs under milder conditions. See, for example, Gorski et al., Investigation of Quantitative SiOH Determination of Silane Treatment of Disperse Silica, Journal of Colloid and Interface Sciencel, 1988, 126 (2), discussing the effect of silane addition agents on polymeric silica based fillers, where they can also be used to modify the silanol groups on the surface of the catalyst support material of the present invention. Similarly, the use of a Lewis acid in greater than the stoichiometric amount required to react with the transition metal compounds of the present invention serves to neutralize excess silanol groups without significant detrimental impact on catalyst preparation and subsequent polymerization.

The polymeric carrier materials to be used according to the invention are preferably polymeric substrates containing hydroxyl functional groups, but such functional group may also be selected from the group consisting of primary alkylamines, secondary alkylamines and other groups that are structurally incorporated into the polymer chain while being capable of acid-base reactions with Lewis acid, such that the ligand filling one coordination site in the aluminum complex is protonated and replaced by a functional group that is part of said polymer. See, for example, functional group-containing polymers described in U.S. Patent No. 5,288,677, the contents of which are incorporated herein by reference.

• · · · ’♦ · · · · 9 · · • · · · · · *

Other carrier materials suitable for use in the present invention include alumina, alumina, magnesium oxide, titanium dioxide, zirconia, magnesium chloride, montmorillonite, phyllosilicate, zeolites, talc, clays, silica containing chromium, silica-titanium dioxide and porous acrylate polymers.

In another embodiment of the invention, one or more olefins, preferably one or more olefins containing from 2 to 30 carbon atoms or one or more α-olefins, preferably ethylene or propylene or mixtures thereof, are prepolymerized in the presence of a catalytic metal compound containing a member of the 15th group of the periodic system of elements and / or metallocene-based catalysts with sterically bulky ligand that are deposited on a suitable support material. Said prepolymerization may be carried out batchwise (i.e. discontinuously) or continuously in the gas phase, in solution or in suspension, including polymerization at elevated pressure. Said prepolymerization may be carried out with any olefin monomer or a mixture of these monomers and / or in the presence of any molecular weight regulating agent of the resulting polymer, such as hydrogen. Examples of prepolymerization processes are described in U.S. Patent Nos. 4,748,221, 4,789,359,

US 4,923,833, US 4,921,825, US 5,283,278 and US 5,705,578, in European Patent No. EP 0 279 863.a in International Publication No. WO 97/44371, the contents of which are incorporated herein by reference.

9 9 · • ·· · 9 9 9 9 • · 9 9 9 «

9·*? 9 · · ·

9 9 · · · «· 9 99 9999

Injection of a solution of a metal compound containing the element z

15 Dec groups of the periodic system of elements

In a further embodiment of the present invention, the catalytic metal compound comprising a Group 15 element and an activating agent is fed to a slurry or gas phase polymerization reactor in a liquid carrier, preferably in the form of a solution. The catalyst and the activating agent of the invention may be injected separately or together and may be mixed together immediately prior to the reactor feed or may be contacted with each other for a longer time prior to the feed to the reactor. Preferred liquid carriers include alkanes, preferably pentane, hexane, isopentane, toluene, cyclohexane, isopentane, heptane, octane, isohexane and the like. Particularly preferred liquid carriers are hexane, pentane, isopentane and toluene.

Said catalyst system, metal compounds and / or activating agent is preferably injected into the reactor in the form of one or more solutions. In one embodiment, a solution of activated metal compounds in an alkane such as pentane, hexane, toluene, isopentane and the like is fed to a slurry or gas phase reactor. According to a further embodiment, said catalyst system or said components are injected into the reactor in the form of a suspension or an emulsion. In another embodiment, the transition metal compound of the present invention is contacted with an activating agent, such as modified methylalumoxane, in a solvent just prior to being injected into the polymer reactor in the gas phase or in suspension. In another embodiment of the invention, the solution of the metal compound of the invention is mixed with the solution

<img file="CZ20021402A3_D0018.tif" />

4 t

of the activating agent, the resulting mixture is allowed to react for some time and then injected into the above reactor. Preferably, the reaction time of the catalyst of the present invention with the activating agent is at least 1 second, preferably at least 5 minutes, and even more preferably from 5 to 60 minutes, before being injected into the reactor. Said catalyst and activating agent are usually present in the solution at a concentration of from 0.0001 to 0.200 mol / liter, preferably from 0.001 to 0.05 mol / liter, more preferably from 0.005 to 0.025 mol / liter. Generally, the metal compound and activating agent of the present invention are mixed together in a ratio of from about 1000: 1 to about 0.5: 1. In a preferred embodiment of the invention, the metal compound and the activating agent of the present invention are mixed together in a ratio of from about 300: 1 to about 1: 1, preferably from about 10: 1 to about 1: 1; preferably from about 1: 1 to about 10: 1 and in the case of using aluminum compounds (such as diethylaluminum chloride in admixture with water) said ratio is preferably from about 0.5: 1 to about 10: 1.

According to another embodiment of the present invention, the catalyst system consists of a transition metal compound (catalyst) and / or activating agent (cocatalyst), which are preferably injected into the reactor in the form of a solution. Solutions of said metal compounds are prepared by dissolving the catalyst in any solvent such as alkane, toluene, xylene, etc. Said solvent may be pre-purified to remove any catalytic poisons that could affect the activity of the catalyst, the group including traces of water and / or oxygen compounds. Purification of the solvent may be achieved, for example, by the use of:

<img file="CZ20021402A3_D0019.tif" />

Activated alumina and activated copper catalyst supported on a suitable support. The catalyst of the present invention is preferably completely dissolved to form a homogeneous solution. Both the catalyst and the activating agent can be dissolved in the same solvent if desired. After dissolution of the catalyst, the resulting solution can be stored until use.

In terms of polymerization, it is preferred that the catalyst of the invention be mixed with the activating agent prior to injection into the reactor. It is further possible to add additional solvents to the catalyst solutions (directly on the production line or off-line), to the activating agent (directly on the production line or off-line) or to the activated catalyst (s).

In a preferred embodiment, the productivity of the catalyst system of the present invention is 10,000 grams of polymer per gram of catalyst per hour.

The catalyst system of the present invention injected in solution as described above has excellent performance in a wide range of reactor conditions and can be used to produce polymers having a melt flow index of from 0.2 grams / 10 minutes to 3 grams / 10 minutes; having a density in the range of 0.950 grams / cm³ up to 0.916 grams / cm³. When using the catalyst system of the present invention, no problems of agglomeration or layering of the resulting polymer were noted during a 10-day continuous operation on a pilot scale. It is also an advantage of the invention that there is no or only a small amount of clogging of the reactor. No layers, lumps, or large polymer particles were observed during or after the polymerization process. Also, no traces of polymer deposition were observed on the internal walls of the reactor or in the gas circulating piping. Also, there was no increase in the pressure drop along the heat exchanger, in the circulating gas compressor or in the gas distribution plate throughout the process.

Injection of mixed catalyst system solutions

According to another embodiment of the present invention, the mixed catalyst systems and / or the activating agent (cocatalyst) are injected into the reactor in the form of a solution. Solutions of said metal compounds are prepared by dissolving the catalyst in any solvent such as alkane, toluene, xylene, etc. Said solvent may be pre-purified to remove any catalytic poisons that could affect the activity of the catalyst, the group including traces of water and / or oxygen compounds. Purification of the solvent may be achieved, for example, by using activated alumina and an activated copper catalyst supported on a suitable support. The catalyst of the present invention is preferably completely dissolved to form a homogeneous solution. Both the catalyst and the activating agent can be dissolved in the same solvent if desired. After dissolution of the catalyst, the resulting solution can be stored until use.

In terms of polymerization, it is preferred that the catalyst of the invention be mixed with the activating agent prior to injection into the reactor. It is also possible to add more:

This to solvents in catalyst solutions (directly on the production line or off-line), to the activating agent (directly on the production line or off-line), or to the activated catalyst (s). ům. See. U.S. Patent Nos. 5,317,036 and 5,693,727 and European Patent Application Publication No. EP 0 593 083, the contents of which are incorporated herein by reference, and which disclose systems for injecting solutions into a reactor. There are many different configurations that can be used to mix catalysts and activating agents.

The catalyst systems, metal compounds and / or activating agent (s) of the present invention can be fed to the reactor in one or more solutions. Said metal compounds can be activated independently, either in series or together. In one embodiment, a solution of two activated metal compounds of the invention in an alkane such as pentane, hexane, toluene, isopentane and the like is injected into a gas phase or slurry reactor. In another embodiment, the catalyst system or components of the present invention may be injected into the reactor as a slurry or emulsion. In another embodiment, the second metal compound of the invention is contacted with the above-described activating agent, such as modified methylalumoxane, in solution and just prior to injecting the solution into the gas phase, slurry, or solution polymerization reactor. A metal compound solution containing the element of 15. of the Periodic Table of the Elements are mixed with a solution of said second compound and activator and subsequently injected into the reactor.

In the schemes described below, stream A is a catalyst or mixture of catalysts and stream B is a different catalyst or mixture of catalysts. The catalyst mixtures in streams A and B may consist of the same catalysts, which are mixed in different proportions. It should further be noted that in many places additional solvents or inert gases may be added to streams A and B.

Scheme 1: Streams A and B together with the activating reagent are mixed together outside the production line and the resulting mixture is subsequently injected into the reactor. This diagram is shown in the attached Figure 1.

Scheme 2: Streams A and B mix together outside the production line.

An activating agent is added directly to the resulting mixture on the production line and the resulting mixture is injected into the reactor. This diagram is shown in the attached Figure 2.

Scheme 3: Stream A or B is contacted (off-line) with the activating agent, and stream A or B is added directly to the resulting mixture prior to entering the reactor. This scheme is shown in Figure 3.

Scheme 4: Stream A or B is contacted (directly on the production line) with the activating agent, and stream A or B is added directly to the resulting mixture directly on the production line prior to entering the reactor. This diagram is shown in Figure 4.

Scheme 5: Both streams A and B are contacted off-line with the activating agent. Subsequently, stream A containing the activating agent is contacted directly on the production line prior to entering the reactor with stream B containing the activating agent. This diagram is shown in the attached Figure 5.

Scheme 6: Both streams A and B are contacted directly with the activating agent directly on the production line. Subsequently, the activator-containing stream A is contacted directly on the production line with the activator-containing stream B before entering the reactor. (This arrangement is advantageous because it is possible to independently control the ratio of the A to the B stream and the ratio of the activating agent to the A stream and the ratio of the activating agent to the B stream). This diagram is shown in the attached Figure 6.

Scheme 7: In this case, stream A or B is contacted (directly on the production line) with the activating agent, while the separate solution A or B is contacted with the activating agent outside the production line. Subsequently, both streams A or B and the activating agent are contacted directly on the production line before entering the reactor. This diagram is shown in the attached Figure 7.

Scheme 8: Stream A is directly contacted with stream B directly on the production line. Subsequently, an activating agent is fed directly to the mixture of A and B directly on the production line. This diagram is shown in the attached Figure 8.

Scheme 9: Stream A is activated off-line using an activating agent. Thereafter, stream A containing the activating agent is contacted directly on the production line with stream B. To the resulting mixture of stream A, B and activating agent, a further proportion of activating agent is added directly on the production line. This diagram is shown in the attached Figure 9.

«· This to ** * · in • *

<img file="CZ20021402A3_D0020.tif" />

to · * * «· * · to i to · to« to · ·

In all the arrangements described above, means may be used to ensure complete mixing of the individual components and / or to provide a certain residence time. For example, mixing blades or worms may be used to mix the components, or pipelines of a certain length may be used to achieve the desired contact time or residence time. By "directly on the production line" is meant that the described material is present in a pipe, tube or vessel that is directly or indirectly connected to the reactor system. By &amp; quot; off-line &amp; quot; is meant that the described material is contained in a pipe, tube, or vessel that is not connected to the reactor system.

In another embodiment, the present invention relates to a process for the polymerization of olefins in a gas-phase polymerization reactor in which at least two catalysts and at least one activating agent are injected, the catalysts and activating agent being injected using a liquid carrier. Preferably, the catalysts and the activating agent (a) are mixed together in a liquid carrier prior to injection into the reactor.

In a further embodiment of the present invention, the catalysts are mixed together in a liquid carrier, then fed to a distribution device that is connected to the reactor and then the activating agent (a) is fed to the distribution device, wherein the activating agent (a) is they can be introduced into said composition both at the same site as the catalysts and at a completely different site. In another embodiment of the invention, said catalysts are contacted together in a liquid carrier and then one or more activating agents are added to the liquid carrier.

According to another embodiment of the present invention, a liquid carrier comprising said catalysts and an activating agent (a) is fed to a liquid carrier injection apparatus into said polymerization reactor. In another variation, the catalysts and the liquid carrier are fed to the apparatus before the activating agent is fed to the apparatus.

In another preferred embodiment of the present invention said composition comprising a liquid carrier forms a liquid stream that flows or is sprayed into the reactor.

In a further preferred embodiment of the present invention, at least one catalyst, at least one activating agent and a liquid carrier are fed to the reactor injection apparatus, and after the first catalyst and activating agent is fed to the apparatus, further catalyst (s) are fed to the apparatus. .

Polymerization process according to the invention

The catalyst compositions, catalyst systems, mixed catalyst systems, supported catalyst systems, or solution sprayed catalyst systems of the present invention described above are suitable for use in any polymerization process. The polymerization process of the present invention comprises solution, gas phase or suspension polymerization, or a combination thereof, most preferably gas phase or suspension polymerization, and even more preferably, the polymerization process of the present invention comprises the use of a single reactor, most preferably a single reactor for polymerization. gas phase.

One aspect of the present invention are slurry or gas phase polymerization or copolymerization reactions comprising polymerization of one or more monomers containing from 2 to 30 carbon atoms, preferably from 2 to 12 carbon atoms, and more preferably from 2 to 8 carbon atoms. The process of the present invention is particularly suitable for copolymerization reactions comprising the polymerization of one or more olefin monomers selected from the group consisting of ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1 decene, 3-methyl-1-pentene, 3,3,5-trimethyl-1-hexene and cyclic olefins or mixtures thereof. Other monomers may include vinyl monomers, diolefins such as dienes, polyene monomers, norbornene monomers, norbornadiene monomers. Preferably, a copolymer of ethylene and at least one comonomer selected from the group consisting of α-olefins containing from 4 to 15 carbon atoms, preferably from 4 to 12 carbon atoms, more preferably from 4 to 8 carbon atoms, and most preferably from 4 to 7 carbon atoms, is produced. . In another embodiment of the present invention, it is possible to polymerize or copolymerize the geminally disubstituted olefins described in WO 98/37109.

In another embodiment of the present invention, ethylene or propylene is polymerized with at least two different comonomers to form a terpolymer. A group of preferred comonomers according to this

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The invention comprises a mixture of α-olefin monomers containing from 4 to 10 carbon atoms, more preferably from 4 to 8 carbon atoms, optionally with at least one pulp monomer. Preferred terpolymers of the present invention include mixtures such as ethylene / 1-butene / 1-hexene, ethylene / propylene / 1-butene, propylene / ethylene / 1-hexene, ethylene / propylene / norbornene, and the like.

A particularly preferred embodiment of the present invention relates to the polymerization of ethylene and at least one comonomer containing from 3 to 8 carbon atoms, preferably from 4 to 7 carbon atoms. Particular examples of such comonomers are 1-butene, 4-methyl-1-pentene, 1-hexene and 1-octene, with 1-hexene and / or 1-butene being the most preferred comonomers.

The gas phase polymerization process of the present invention typically utilizes a continuous cycle in which one portion of the cycle, consisting of a reactor system circulating a gas stream, referred to as a recycle stream or fluid, is heated in the reactor by the heat released by the reactor. polymerization. This heat is removed from the recycle mixture in another part of the circuit by means of a cooling system located outside the reactor. Typically, in a fluidized bed gas phase polymerization process, a gas stream containing one or more monomers is continuously circulated through the fluidized bed in the presence of a catalyst and under conditions where the desired reaction occurs. The gas stream is removed from the fluidized bed and recycled back to the reactor. In parallel with this process, the polymer product is removed from the reactor and the fresh monomer is injected to replace the polymerized monomer. (See. for example, patents • · »·»

<img file="CZ20021402A3_D0023.tif" />

US 4,543,399, US 4,588,790, US 5,028,670, US 5,317,036, US 5,352,749, US 5,405,922,

US 5,436,304, US 5,453,471, US 5,462,999, US 5,616,661 and US 5,668,228, which are incorporated herein by reference).

The pressure in the gas-phase polymerization reactor may vary from about 69 kilopascals (about 10 psig) to about 3448 kilopascals (about 500 psig), preferably from about 690 kilopascals (about 100 psig) to about 2759 kilopascals (about 500 psig). 400 psig), preferably in the range of about 1379 kilopascals (about 200 psig) to about 2759 kilopascals (about 400 psig), more preferably, in the range of about 1724 kilopascals (about 250 psig) to about 2414 kilopascals (about 350 psig).

The temperature in the gas-phase polymerization reactor may vary from about 30 ° C to about 120 ° C, preferably from about 60 ° C to about 115 ° C, more preferably from about 75 ° C to about 110 ° C. C, and most preferably in the range of about 85 ° C to about 110 ° C. Temperature variations in polymerization can be used as a tool to alter the properties of the resulting polymer product.

The productivity of the catalyst or catalyst system of the present invention is affected by the partial pressure of the main monomer. Preferably, the molar content of the major monomer of the present invention, i.e. ethylene or propylene, preferably ethylene, is from about 25 mole percent to about 90 mole percent, the partial pressure of said monomer being in the range of about 4 to about 4 mole percent. 4

4 »44 ♦·» »-».·» « *· ♦ ·· ♦·'·

517 kilopascals (about 75 psia) to about

2069 kilopascals (approximately 300 psia) which are the usual conditions of the gas phase polymerization process. In one embodiment, the ethylene partial pressure is from about 1517 kilopascals to about 1653 kilopascals (from about 220 psi to 240 psi). In another embodiment of the invention, the molar ratio of hexenes to ethylene in the reactor is from 0.03: 1 to 0.08: 1.

In another embodiment of the present invention, it is possible to produce from more than 227 kilograms of polymer / hour (i.e., more than 500 lb of polymer / hour) to about 90,900 kilograms or more of polymer by the reactor used in the process and the method of the present invention. per hour (i.e., about 200,000 lbs or more of polymer / hour), preferably from greater than 455 kilograms of polymer / hour (i.e., greater than 1000 lbs of polymer / hour), more preferably from greater than 4540 kilograms of polymer / hour (i.e. more than 10,000 lb of polymer / hour), more preferably from more than 11,300 kilograms of polymer / hour (ie more than 25,000 lb of polymer / hour), even more preferably from more than 15,900 kilograms of polymer / hour (ie more than 35,000 lb of polymer / hour), more preferably more than 22,700 kilograms of polymer / hour (i.e., more than 50,000 lb of polymer / hour) and more preferably from more than 29,000 kilograms of polymer / hour (i.e., more than 65,000 lb of polymer) up to 45,500 kilograms of polymer per hour (i.e. more than 100,000 lb polymer / hour).

Other gas phase polymerization processes considered to be methods of the present invention include those described in United States Patent Nos.

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5, 627,242; US 5,665,818 and US 5,677,375, in European patent applications EP-A-0 794 200; EP-A-0 802 202 and EP-B-634 421, all of which are incorporated herein by reference.

The slurry polymerization typically uses a pressure in the range of from 103 kilopascals to 5068 kilopascals (i.e., from about 1 atmosphere to about 50 atmospheres) and even more, with a temperature ranging from 0 ° C to about 120 ° C. Suspension polymerization results in a suspension of a solid, particulate polymer in a liquid polymerization medium containing a solvent to which ethylene is added along with the comonomers and the catalyst. Said solvent-containing slurry is intermittently or continuously removed from the reactor, where the volatile components are separated from the polymer, which are recycled, optionally after distillation, back into the reactor. The liquid solvent to be used in said polymerization medium is usually an alkane containing from 3 to 7 carbon atoms, preferably a branched alkane. The medium used should be liquid and relatively inert under polymerization conditions. If a propane medium is used, said process must be carried out at a pressure and temperature that is above the critical temperature and the critical pressure of said reaction solvent. Preferably, a hexane or isobutane medium is used according to the invention.

In one embodiment, the preferred polymerization process is polymerization in which solid polymer particles or slurry polymerization are maintained at a temperature lower than that at which the polymer would dissolve. Such procedures

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are well known in the art and have been described, for example, in U.S. Patent No. 3,248,179, which is incorporated herein by reference. In the method for forming solid polymer particles, the temperature is preferably maintained in the range of about 85 ° C (about 185 ° F) to about 110 ° C (about 230 ° F). Slurry polymerization preferably uses two methods, one of which uses a loop reactor, while the other uses several stirred reactors connected in series, in parallel, or a combination of the individual reactor connections. Examples of slurry polymerization processes include, but are not limited to, a continuous loop process and a stirred reactor process. Other examples of suspension polymerization methods have also been described in U.S. Patent No. 4,613,484, which is incorporated herein by reference.

In another embodiment of the present invention, the slurry polymerization is carried out continuously in a loop reactor.

The catalyst in the form of a suspension in isobutane or in the form of a dry, free-flowing powder is regularly fed into a reactor loop which is itself filled with a circulating suspension of increasing polymer particles in a solvent which is isobutane containing monomer and comonomer. Optionally, hydrogen may be introduced into the system to control the molecular weight of the polymer formed. The pressure in said reactor is maintained at about 3620 kilopascals (about 525 psig) to about 4309 kilopascals (625 psig) and the reactor temperature is in the range of about 60 ° C (about 140 ° F) to about

<img file="CZ20021402A3_D0025.tif" />

104 ° C (about 220 ° F), depending on the desired density of the polymer formed. Reaction heat is dissipated through the loop wall because most of this reactor is in the form of a double-jacketed pipeline. The slurry is allowed to leave the reactor at regular intervals or continuously to a heated low pressure firing vessel, rotary dryer and nitrogen purge column to remove the isobutane solvent and any unreacted monomer and comonomers. The resulting hydrocarbon-free powder is subsequently used in various products.

With the slurry polymerization reactor and the process, more than 907 kilograms of polymer / hour (i.e., more than 2000 lb of polymer / hour), more preferably more than 2268 kilograms, can be produced by the slurry polymerization reactor. and more preferably more than 4540 kilograms of polymer / hour (i.e., more than 10,000 lb of polymer / hour). In another embodiment of the invention, it is possible to produce from more than 6804 kilograms of polymer / hour (i.e., more than 15,000 lbs polymer / hour), preferably from more than 11 340 kilograms of polymer, in a slurry polymerization reactor of the present invention. per hour (i.e., greater than 25,000 lbs polymer / hour) to about 45,500 kilograms of polymer / hour (i.e. greater than 100,000 lbs polymer / hour).

In another embodiment of the slurry polymerization process of the present invention, the total reactor pressure is in the range of 2758 kilopascals (i.e. 400 psig) to 5516 kilopascals. * 99 · 9 9 · 9 · 9 · · 9 (ie 800 psig) , preferably in the range of 3103 kilopascals (i.e., 450 psig) to about 4827 kilopascals (i.e., approximately

700 psig), more preferably in the range of 3448 kilopascals (i.e., 500 psig) to about 4482 kilopascals (i.e., approximately

650 psig), and most preferably in the range of about

3620 kilopascals (i.e., about 525 psig) to 4309 kilopascals (i.e., about 625 psig).

In another embodiment of the slurry polymerization of the present invention, the concentration of ethylene in said reactor fluid medium is in the range of about 1 weight percent to 10 weight percent, preferably in the range of about 2 weight percent to about 7 weight percent, more preferably in the range of about 2 weight percent. 5 weight percent to about 6 weight percent, most preferably in the range of about 3 weight percent to about 6 weight percent.

Another method of the present invention is a process, preferably gas phase or slurry polymerization, which is carried out in the absence or substantially free of any scavengers such as triethyl aluminum, trimethyl aluminum, triisobutyl aluminum, tri-n-hexyl aluminum and diethylaluminum chloride, dibutylzinc and the like . Such a method has been described in WO 96/08520 and US 5,712,352, the contents of which are incorporated herein by reference.

In a preferred embodiment of the present invention, a slurry of aluminum stearate in mineral oil is injected into the reactor, and

<img file="CZ20021402A3_D0026.tif" />

either separately or together with the first and / or second metal complex according to the invention and / or together with the activating agent described above. A more detailed discussion of the use of aluminum stearate type additives is given in U.S. Patent Application Serial No. 09 / 113,261 of July 10, 1998, the contents of which are incorporated herein by reference.

In an embodiment of the invention wherein the second metal compound of the present invention and the metal compound containing a Group 15 element are added to the reactor sequentially, it is preferred that said second metal compound is added and / or activated first and said compound A metal containing element 15 of the Periodic Table of Elements is added to the reactor and / or activated second.

In another embodiment of the present invention, the residence time of the catalyst composition of the present invention is from about 3 hours to about 6 hours, preferably from about

3.5 hours to about 5 hours.

The molar ratio of comonomer to ethylene of the present invention, referred to as C_x/C₂where C_x indicates the amount of comonomer and C₂ refers to an amount of ethylene, ranging from about 0.001 to 0.0100, and more preferably from about 0.002 to 0.008.

The melt index (and other properties) of the polymer produced according to the invention can be varied by adjusting the hydrogen concentration in the polymerization system by:

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1) varying the amount of the first catalyst in the polymerization system; or

2) varying the amount of second catalyst in the polymerization system; or

3) adding hydrogen to the polymerization process; or

4) varying the amount of liquid and / or gas being removed and / or discharged from the reactor; or

5) changes in the amount and / or composition of the recovered liquid and / or recovered gas that are returned to the polymerization process, wherein said liquid or said gas is recovered from the polymer taken from the polymerization process; or

6) use of a hydrogenation catalyst in the polymerization process; or

7) polymerization temperature changes; or

8) changes in ethylene partial pressure in the polymerization process; or

9) changing the ratio of ethylene to hexene in the polymerization process and / or

10) changing the ratio of activating agent to transition metal in the activating sequence.

The hydrogen concentration in the above reactor is from about 100 ppm to 5000 ppm, preferably from 200 ppm to 2000 ppm, more preferably from 250 ppm to 1900 ppm, more preferably from 300 ppm to 1800 ppm, more preferably from 350 ppm to 1700 ppm, more preferably from 400 ppm to 1600 ppm, more preferably from 500 ppm to 1500 ppm, more preferably from 500 ppm to 1400 ppm, more preferably from 500 ppm to 1200 ppm, more preferably from 600 ppm to 1200 ppm, more preferably from 700 ppm to 1100 ppm and even more preferably from 800 ppm up to 1000 ppm.

<img file="CZ20021402A3_D0027.tif" />

The hydrogen concentration in the reactor is inversely proportional to the weight average molecular weight (M_w) of the resulting polymer.

The polymer of the present invention

The polymers produced by the methods of the present invention can be used in many different products and end applications. The group of polymers produced by the methods of the present invention includes polyethylene and bimodal polyethylene produced in a single reactor using the mixed catalyst system of the present invention. In addition to bimodal polymers, mono- or multimodal polymers also belong to the group of polymers produced using the mixed catalyst system of the present invention.

The use of a metal compound containing a Group 15 element alone produces high molecular weight (Mw) polymers._w), such as polymers having a molecular weight greater than 100,000, preferably greater than 150,000, preferably greater than 200,000, preferably greater than 250,000, preferably greater than 300,000. The use of the second metal compound alone of the present invention results in low weight average molecular weight polymers such as polymers having a molecular weight of less than 80,000, preferably less than 70,000, preferably less than 60,000, preferably less than 50,000, preferably less more than 40,000, preferably less than 30,000, preferably less than 20,000 and greater than 5,000, more preferably less than 20,000, but greater than 10,000.

The polyolefins, in particular the polyethylenes produced by the process of the present invention, have a density in the range of 4MMH.

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0.88 grams / cm³ up to 0.97 grams / cm³ (measured in accordance with ASTM 2839). Preferably, it is possible to produce polyethylenes having a density in the range of 0.910 grams / cm³ up to 0.965 grams / cm³more preferably in the range of 0.915 gram / cm³ up to 0.960 grams / cm³more preferably in the range of 0.920 gram / cm³ up to 0.955 grams / cm³. In some cases, it may be advantageous to produce a polymer having a density in the range of 0.915 grams / cm³ up to 0.940 grams / cm³In other cases it may be advantageous to produce a polymer with a density in the range of 0.930 grams / cm³ up to 0.970 grams / cm³.

In a preferred embodiment, the melt index is I₂ (measured according to ASTM D-1238, condition E, 190 ° C) of a polyolefin produced according to the invention in the range of about 0.01 gram / 10 minutes to about 1000 grams / 10 minutes, preferably the polyolefin is an ethylene homopolymer or copolymer . In a preferred embodiment of the present invention, when the produced polymer is used to produce certain articles such as films, tubes, shaped articles, and the like, it is preferred that the melt index of the polymer be 10 grams / 10 minutes or less. For the production of some types of films and moldings, it is preferred that the melt index is 1 gram / 10 minutes or less. A preferred polymer is polyethylene having a melt index ranging from 0.01 gram / 10 minutes to 10 grams / 10 minutes.

In a preferred embodiment, the melt index is I₂(measured according to ASTM D-1238, condition F, 190 ° C) of the polymer produced according to the invention ranging from

0.1 grams / 10 minutes to 10 grams / 10 minutes, preferably in the range of 0.2 grams / 10 minutes to 7.5 grams / 10 minutes, more preferably the index is 2 grams / 10 minutes or less, preferably

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1.5 gram / 10 minutes or less, preferably 1.2 gram / 10 minutes or less, more preferably in the range of 0.5 gram / 10 minutes to 1.0 gram / 10 minutes, even more preferably in the range of 0.6 gram 10 minutes to 0.8 grams / 10 minutes.

In another embodiment of the invention, the melt index (MIR) ratio I21 / I2 is 80 or more, preferably 90 or more, preferably 100, preferably 125 or more.

According to another embodiment of the present invention, the melt index is I₂i (measured according to ASTM D-1238, condition F,

190 ° C) of the polymer produced according to the invention grams / 10 minutes or less, preferably 1.5 grams / 10 minutes or less, preferably 1.2 grams / 10 minutes or less, more preferably in the range of 0.5 grams / 10 minutes to 1 0 grams / 10 minutes, more preferably in the range of 0.6 grams / 10 minutes to 10 grams / 10 minutes

0.8 grams / 10 minutes and the melt index ratio I21 / I2 is 80 or more, preferably 90 or more, preferably 100, preferably 125 or more, and in addition the polymer has the following characteristics:

(a) molecular weight distribution (M_w/ M_n) in the range of from 15 to 80, preferably from 20 to 60, preferably from 20 to 40, wherein the individual molecular weights M_w and M_n is measured as described in the Examples;

(b) weight average molecular weight (M_w180,000 or more, preferably 200,000 or more, more preferably 250,000 or more, and even more preferably 300,000 or more;

(c) a density (determined in accordance with ASTM 2839) of 0.94 grams / cm³ up to 0.970 grams / cm³preferably at

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4 4 4 · 4 • 4 4 4 4 • 4 ranges from 0.945 grams / cm³ up to 0.965 grams / cm³preferably in the range of 0.950 grams / cm³ up to 0.960 grams / cm³;

(d) a residual transition metal content of 5.0 ppm or less, preferably 2.0 ppm or less, preferably 1.8 ppm or less, preferably 1.6 ppm or less, preferably 1.5 ppm or less, preferably 2.0 ppm or less of Group 4 metal, preferably 1.8 ppm or less of metal

4. Group 4, preferably 1.6 ppm or less of Group 4 metal, preferably 1.5 ppm or less of Group 4 metal. groups of the Periodic Table of the Elements, preferably 2.0 ppm or less zirconium, preferably 1.8 ppm or zirconium, preferably 1.6 ppm or less zirconium, preferably 1.5 ppm or less zirconium (as measured by inductively coupled plasma optical emission spectroscopy (ICPAES) )), the measurement being carried out against commercially available standards, whereby the individual samples are heated to complete decomposition of all organic matter, the solvent used being nitric acid and when a carrier material is present, said solvent comprises an additional acid which serves to dissolve the carrier (such as hydrofluoric acid to dissolve the silica);

(e) it contains 35 weight percent or more of the high molecular weight component as determined by particle size chromatography, preferably it contains 40 weight percent or more of said component. In a particularly preferred embodiment, the higher molecular weight component is present in an amount of from 35 to 70 weight percent, more preferably from 40 to 60 weight percent, in the polymer of the invention.

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In a preferred embodiment, the catalyst system described above is used to produce polyethylene with a density between 0.94 grams / cm³ and 0.970 grams / cm³ (measured according to ASTM D-2839), whose melt index I₂ is 0.5 grams / 10 minutes or less.

In another embodiment, the catalyst system described above is used to produce polyethylene whose melt index I_2iit is less than 10 grams / 10 minutes and has a density ranging from about 0.940 grams / cm³ up to 0.950 grams / cm³ or whose melt index₂₁ is less than 20 grams / 10 minutes and has a density of about 0.945 grams / cm³ or less.

In another embodiment, the polymer of the present invention is used to make tubes by known methods. In this case, the polymer used to make the tubes has a melt index I_2i from about 2 grams / 10 minutes to about 10 grams / 10 minutes, preferably from about 2 grams / 10 minutes to about 8 grams / 10 minutes.

In another embodiment, the tubes of the present invention meet the quality requirements of the ISO standard.

In another embodiment, the catalyst of the present invention is used to produce polyethylene pipes having a service life of at least 50 years at 20 ° C, using water as the internal test medium and water or air as the external environment (Hydrostatic (tangent)) voltage measured according to ISO TR 9080).

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In another embodiment of the present invention, the resultant polymer has a scratch resistance test (that is, a slow crack propagation test) of more than 150 hours at 3.0 megapascals, preferably more than 500 hours at 3.0 megapascals and still more. more preferably, more than 600 hours at a pressure of 3.0 megapacals (measured in accordance with ASTM-F1473).

In another embodiment of the invention, the catalyst composition of the present invention is used to produce polyethylene pipes having a predicted S-4 T value._C for a pipe length of 110 millimeters less than -5 ° C, preferably less -15 ° C and more preferably less than -40 ° C (measured according to ISO DIS 13477 / ASTM F1589).

According to another embodiment of the present invention, the produced polymer can be extruded at a rate of greater than about 3 kilograms / hour / centimeter of the perimeter of the slot (i.e. greater than about 17 pounds / hour / inch of perimeter of the slot) a slot circumference (i.e., greater than about 20 pounds / hour / inch of the slot circumference) and more preferably greater than about 3.9 kilograms / hour / centimeter of the slot circumference (i.e. greater than about 22 pounds / hour / inch of circumference).

The polyolefins of the present invention can be formulated into films, shaped articles (including tubes), plates, wire and cable coating materials and the like. Said films can be produced by conventional methods known in the art, the group of which comprises extrusion, co-extrusion, lamination, blow molding and casting. The film may be obtained in the form of a flat film or by a process for producing a film in the form of a sleeve, followed by orientation of the film in the direction of one axis or two mutually perpendicular directions in the plane of the film, to the same or different extent. The extent of said orientation may be the same in both directions or may be different in each direction. A group of particularly preferred processes for processing the polymers of the present invention to form films include extruding or co-extruding to a blown or flat film manufacturing machine.

In a further embodiment of the present invention, the produced polymer is processed into a film by known methods. In this case, the melt index is I₂polymers of the present invention in the range of about 2 grams / 10 minutes to about 50 grams / 10 minutes, preferably in the range of about 2 grams / 10 minutes to about 30 grams / 10 minutes, more preferably in the range of about 5 grams / 10 minutes up to about 15 grams / 10 minutes and even more preferably ranging from about 5 grams / 10 minutes to about 10 grams / 10 minutes.

According to another embodiment of the present invention, the tear resistance of the film having a thickness of 13 microns (0.5 mil) in the machine direction (MD) is in the range of about 5 grams / mil to 25 grams / mil, preferably in the range of about 15 grams / mil to 25 grams / mil and more preferably in the range of about 20 grams / mil to 25 grams / mil.

The films made in accordance with the present invention may further comprise additives such as glidants, anti-blocking agents, antioxidants, pigments, fillers, antifouling agents, stabilizers ultraviolet protection agents, antistatic agents, polymer processing agents, neutralizers, lubricants, surfactants, pigments, dyes, and nucleating agents. Preferred additives include silica, synthetic silica, titanium dioxide, polydimethylsiloxane, calcium carbonate, metal atom stearates, calcium stearate, zinc stearate, clay, barium sulfate, diatomaceous earth, wax, carbon black, flame retardants, low molecular weight polymers, glass beads and the like. Said additives are usually used in an amount sufficient for their effective action, which amounts are well known in the art and can be, for example, from 0.001% by weight to 10% by weight.

In another embodiment of the present invention, the produced polymer is processed by conventional methods into a shaped article, for example by blow molding and injection molding. The polymers of the present invention which are used to produce shaped articles have a melt index of I₂even in the range of about grams / 10 minutes to about 50 grams / 10 minutes and preferably in the range of about 35 grams / 10 minutes to about 45 grams / 10 minutes.

In another embodiment, the polymers of the present invention, including the polymers described above, contain less than 100 ppm ash, more preferably less than 75 ppm and even more preferably less than 50 ppm. In a further embodiment, said ash comprises a negligibly low amount of titanium whose

<img file="CZ20021402A3_D0029.tif" />

the amount is determined by a combination of inductively coupled plasma emission spectroscopy and atomic emission spectroscopy (ICPAES), a method well known in the field of analytical chemistry.

In another embodiment of the invention, the polymers produced contain a nitrogen-containing ligand that can be detected by high resolution mass spectroscopy (HRMS), which is again a well-known analytical method.

Description of the drawings

Figures 1 to 9 show the above-described diagrams of a possible arrangement for injecting the individual catalyst components of the present invention into a polymerization reactor.

DETAILED DESCRIPTION OF THE INVENTION

In order to better understand the nature of the invention, including its selected advantages, the following non-limiting examples are set forth below.

Weight average molecular weight (M_w) and number average molecular weight (M_n) were measured by gel permeation chromatography on a Waters 150 ° C GPC, equipped with differential detectors based on refractive index measurements. Gel permeation chromatography (GPC) columns were calibrated using a series of narrow molecular weight polystyrene standards and the molecular weights were calculated using Mark Houwink coefficients for the polymer.

• · · · • · * • · · « ♦ * • · · · · ·

The molecular weight distribution (MWD) is the ratio M_w/ M_n.

The density was measured in accordance with ASTM D 1505.

The branch distribution distribution index (CDBI) was measured according to the procedure described in published international application number WO 93/03093, except for fractions whose molecular weight was less than 10,000 which were neglected in the calculation.

Melt Flow Index (MI)₂ was measured in accordance with ASTM standard 1238, Condition E, at 190 ° C. Melt Flow Index (MI)₂i was measured in accordance with ASTM standard 1238, Condition F, at 190 ° C.

The melt index ratio (MIR) is the melt index ratio I₂₁ and melt index I₂that have been measured in accordance with ASTM standard 1238.

The comonomer content, expressed in weight percent, was measured by proton NMR spectroscopy.

Impact toughness tested by falling arrow was determined in accordance with ASTM D 1709.

Elmendorf tear resistance in machine direction (MD) and transverse direction (TD) was measured according to ASTM D 1922.

1% secant, ie the modulus of elasticity determined as the secant of the stress-strain curve, was determined in accordance with the standard

ASTM D 822.

The tensile strength and ultimate tensile strength in the machine direction (MD) and in the transverse direction (TD) were measured in accordance with ASTM D 822.

Ductility and ultimate ductility in the machine direction (MD) and in the transverse direction (TD) were measured in accordance with ASTM standard 822-91.

Haze was measured according to ASTM Standard 1003-95, Condition A.

The gloss at 45 ° was measured according to ASTM D 2457.

BUR stands for blow rate.

The impact strength tested by a 26-inch falling arrow was determined in accordance with ASTM D 1709, Method A.

Escorene® LL3002.32 is a linear low-density ethylene-hexene copolymer made in a single gas-phase polymerization reactor and using a Ziegler-Natta catalyst, commercially available from Exxon Chemical Company, Houston, Texas, USA. The density of this polymer is

0.918 grams / cm³, its melt flow index₂ is 2 grams / minute and the branch distribution index (CDBI) of this polymer is less than 65.

9 · 9 · • « · 9

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• · · »

9 ·

9 9

9 9

9999

Exceed® ECD 125 is a linear low density ethylene-hexene copolymer made in a single gas-phase polymerization reactor using a metallocene catalyst, commercially available from Exxon Chemical Company, Houston, Texas, USA. The density of this polymer is 0.91 grams / cm³and its melt index is 1.5 grams / 10 minutes.

Escorene® LL3001.63 is a linear low density ethylenehexene copolymer made in a single gas-phase polymerization reactor using a Ziegler-Natta catalyst, commercially available from Exxon Chemical Company, Houston, Texas, USA. The density of this polymer is

0.918 grams / cm³, its melt flow index₂ is 1.0 gram / minute.

Exceed® 350D60 is a linear low density ethylene-hexene copolymer made in a single gas-phase polymerization reactor and using a metallocene catalyst, commercially available from Exxon Chemical Company, Houston, Texas, USA. The density of this polymer is 0.918 grams / cm³and its melt index is 1.0 grams / 10 minutes.

PPH stands for pounds / hour, mPPH stands for millilibres / hour. The abbreviation "ppmw" refers to units of ppm expressed in parts by weight.

In the examples described in Example I, a mixed catalyst system was used comprising a metal catalyst containing a Group 15 element and a sterically bulky ligand metallocene catalyst.

• · · ·

Example Section I. A mixed catalyst system comprising a metal catalyst comprising a Group 15 element and a sterically bulky ligand metallocene catalyst.

Preparation of indenylzirconium trispivalate

Indenyl zirconium trisivalate, a sterically bulky metallocene compound represented by the general formula (VI), could be prepared by the following chemical reactions:

(1) Zr (NEt₂)₄ + IndH »IndZr (NEt₂)₃ + Et₂NH (2) IndZr (NEt₂)₃ + 3 (CH₃) ₃CCO₂H -&gt; IndZr [O₂CC (CH₃) ] ₃ + Et₂NH where Ind is indenyl and Et is ethyl.

Preparation [(2,4,6-Me₃C6H₂) NHCH₂CH₂] ₂NH (ligand I)

In a 2-liter Schlenk flask was placed a magnetic stirrer, 23.450 grams (0.227 moles) of diethylenetriamine, 90.51 grams (0.455 moles) of 2-brommesitylene, 1.041 grams (1.14 millimoles) of tris (dibenzylideneacetone) dipalladium, 2.123. g (3.41 millimoles) of racemic 2,2'-bis (diphenylphosphino) -1,1'-binaphthyl (racemic BINAP), 65.535 g (0.682 mol) of tert. sodium butoxide and 800 ml of toluene. The reaction mixture was heated to 100 ° C with stirring. After stirring for 18 hours, the reaction was found to be complete by proton NMR spectroscopy. All remaining operations have already been performed in the presence of air. The solvent was removed in vacuo and the residue was dissolved in 1 L of ether. The ether solution was washed three times with 250 ml of water and 500 ml of saturated aqueous sodium chloride solution (in which 180 grams of NaCl was dissolved) and dried over 30 grams of anhydrous magnesium sulfate. Removal of the ether in vacuo gave a red oil, which was dried under vacuum at 70 ° C for 12 hours to give 71.10 g (92 percent) of product.

^X@ 1 H NMR₆D₆) δ 6.83 (s, 4), 3.39 (brs, 2), 2.86 (t, 4),

2.49 (t, 4), 2.27 (s, 12), 2.21 (s, 6), 0.68 (brs, 1).

Preparation of Catalyst A (for the purpose of Example Section I) A 1.5% catalyst solution in toluene was prepared by the following sequence of steps, all operations being carried out in a dry box.

100 grams of purified toluene were weighed into a 1 liter Erlenmeyer flask equipped with a Teflon coated stirrer. 7.28 grams of tetrabenzyl zirconium was added to the toluene and the resulting solution was allowed to stir for 5 minutes, during which time all the solid dissolved. To the solution was added 5.42 grams of ligand I as described above and another 551 grams of purified toluene. The mixture was allowed to stir for 15 minutes, again dissolving all solids. The resulting catalyst solution was transferred to a clean 1 liter Whitey cylinder, which was subsequently labeled, removed from the dry box, and placed in a holder where it was ready for later use.

· ·

4 ·

4 4 · 4 4 4 4

An alternative method for preparing compound 1 {[(2,4,6-Me₃CgH₂) NCH₂CH₂] ₂NH} Zr (CH₂Ph) ₂

A magnetic stirrer was placed in a 500 mL round bottom flask and 41.729 grams (91.56 millimoles) of tetrabenzyl zirconium (Boulder Scientific) and 300 milliliters of toluene were added to the flask in a dry, oxygen-free nitrogen atmosphere. 32.773 g (96.52 millimoles) of solid ligand I, prepared as described above, were added to the mixture over 1 minute with continuous stirring to precipitate the desired product from the mixture. The volume of the suspension was reduced to 100 mL and 300 mL of pentane was added with stirring. The yellow-orange solid was collected by filtration and dried under vacuum to give 44.811 g (80 percent) of the desired product.

NMR (C₆D₆) δ 7.22-6.81 (m, 12), 5.90 (d, 2), 3.38 (m, 2), 3.11 (m, 2), 3.01 (m, 1) 2.49 (m, 4), 2.43 (s, 6), 2.21 (s,

6), 2.18 (s, 6), 1.89 (s, 2), 0.96 (s, 2).

Preparation of Catalyst B (for this Example Section I) A 1% catalyst solution in hexane was prepared by the following sequence of steps, all operations being carried out in a dry box.

To a 1 liter Erlenmeyer flask equipped with a Teflon coated stirrer was charged 1 liter of purified hexane. To the hexane was added 6.67 grams of indenyl zirconium trispivalate as a dry powder. The resulting solution was allowed to stir for 15 minutes, during which time all solids dissolved. The resulting catalyst solution was transferred to a pure catalyst:

• · · · · · ·· ··

<img file="CZ20021402A3_D0031.tif" />

The 1 liter whitey cylinder, which was subsequently labeled, was removed from the dry cabinet and placed in a holder where it was ready for later use.

Example Section I-Comparative Example 1

Ethylene / hexene was prepared in a 35.6 centimeter (14 inch) gas phase polymerization reactor operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18.1 kilograms / hour (i.e., about 40 lbs / hour), hexene was fed to the reactor at a rate of about 0.27 kilograms / hour (i.e. 0.6 lb / hr) and hydrogen was fed to the reactor at a rate

2.25 g / hour (i.e., 5 mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 2.0

3.6 kilograms / hour (i.e. 5-8 PPH). The polymer production rate was about 12.15 kilograms / hour (i.e., about 27 PPH). The reactor was equipped with an overpressure device set at 855 kilograms / hour (i.e. 1900 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone. Learn more about using this type of device. can be found in U.S. Patent No. 5,693,727). A 0.10 centimeter (i.e., 0.041 inch) inner diameter conical nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1% by weight of catalyst A in toluene and a cocatalyst (which was MMAO-3A containing 1% by weight aluminum) were mixed directly on the production line before being injected into the fluidized bed via said nozzle (MMA0). -3A is a solution of modified methylalumoxane in heptane, which is commercially available from Akzo Chemicals, Inc. under the trade name Modified Methylalumoxane type 3A). The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 400: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂1 was 0.28 grams / 10 minutes and its density was 0.935 grams / cm³. The residual zirconium content of 1.63 ppmw was calculated based on the mass balance of the reactor.

Example Section I-Comparative Example 2

Ethylene / hexene was prepared in a pilot reactor for gas phase polymerization with a diameter of 35.6 centimeters (14 inches) operating at 80 ° C, 2.2 megapascal (320 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 19.8 kilograms / hour (i.e., about 37 lbs / hour), hexene was fed to the reactor at a rate of about 0.18 kilograms / hour (i.e. 0.4 lb / hr) and hydrogen was fed to the reactor at a rate of 5.4 g / hr (i.e. 12 mPPH). Ethylene was fed to the reactor at a rate such that its partial pressure in the reactor was still 1.2 megapascal (i.e., 180 psi). The polymer production rate was about 11.25 kilograms / hour (i.e., about 25 PPH). The reactor was equipped with a pressurized device set at a power of approximately 463.5 kilograms / hour (i.e.

♦ ··· ·· 99

9 9 9

9 ♦ • · ·

9999 about 1030 PPH) of recycle gas (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-free zone). Conical nozzle with an inner diameter of 0.14 centimeters (i.e.

0.055 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1 weight percent Catalyst B in hexane was stirred for approximately 15 minutes in a 0.48 centimeter (i.e., 3/16 inch) stainless steel tube with 0.09 kg / hour (i.e. 2 lb / hour). The resulting mixture of Catalyst B and hexene was mixed directly with the cocatalyst (MMA0-3A containing 1 weight percent aluminum) on the production line for approximately 40 minutes. In addition, isopentane and nitrogen were fed to the solution to control the average particle size of the resulting polymer. The whole system passed through the feed nozzle into the fluidized bed. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 300: 1. A bimodal polymer having a melt index of 797 grams / 10 minutes and a density of

0.9678 grams / cm³. The residual zirconium content of 0.7 ppmw was calculated based on the mass balance of the reactor. SEC analysis and deconvolution were performed using four powder distributions, the results of which are shown in Table I.

Example section I-example 3

In a pilot plant for gas phase polymerization with a diameter of 35.6 centimeters (14 inches) operating at 80 ° C, a pressure of 2.2 megapascal (320 psig) and equipped with a water-cooled heat exchanger, was prepared

1111 • it-it

9·

11 11 ethylene / hexene copolymer. Ethylene was fed to the reactor at a rate of about 24 kilograms / hour (i.e., about 53 lb / hour), hexene was fed into the reactor at a rate of about 0.22 kilograms / hour (i.e., about 0.5 lb / hour) and further into the reactor fed hydrogen at a rate of 4 grams / hour (i.e. 9 mPPH). Ethylene was fed to the reactor at a rate such that its partial pressure in the reactor was still 1.52 megapascal (i.e. 220 psi). The polymer production rate was about 11.25 kilograms / hour (i.e., about 25 PPH). The reactor was equipped with a pressurizing device set at a power of about 445.5 kilograms / hour (i.e. about 990 PPH) of recycle gas (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone). Conical nozzle with an inner diameter of 0.14 centimeters (i.e. 0.055 inch) for injection! The catalyst was placed in a gas stream in said plenum. A solution containing 1 weight percent Catalyst B in hexane was stirred for approximately 15 minutes in a 0.48 centimeter (i.e., 3/16 inch) stainless steel tube with 0.09 kg / hour (i.e. 2 lb / hour). The resulting mixture of Catalyst B and hexene was mixed directly with the cocatalyst (MMA0-3A containing 1 weight percent aluminum) on the production line for approximately 20-25 minutes. In a separate stainless steel activation tube, the toluene solution containing 1 weight percent of catalyst A was activated for about 50 to 55 minutes by the co-catalyst, MMAO-3A. The two independently activated solutions were stirred together for 4 minutes to form a single process catalyst stream. The amount of Catalyst A in the feed solution was about 40 to 45 mole percent. In addition, the solution was introduced into the solution.

<img file="CZ20021402A3_D0032.tif" />

• ·

0 ·

0000 isopentane and nitrogen were fed to control the average particle size of the resulting polymer. The whole system passed through the feed nozzle into the fluidized bed. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 300: 1. A bimodal polymer having a melt index of 0.045 grams / 10 minutes and 7.48 grams / 10 minutes and a density of 0.9496 grams / cm was obtained.³. The residual zirconium content was

1.7 ppmw, was calculated based on the mass balance of the reactor. SEC analysis and deconvolution were performed using seven to eight powder distributions, the results of which are shown in Table I.

Example Section I-Example 4

Ethylene / hexene was prepared in a 35.6 centimeter (14 inch) gas phase polymerization pilot reactor operating at 85 ° C, 2.2 megapascal (320 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 22.7 kilograms / hour (i.e., about 50 lb / hour), hexene was fed to the reactor at a rate of about 0.32 kilograms / hour (i.e. 0.7 lb / hr) and hydrogen was fed to the reactor at a rate of 4.95 g / hr (i.e.

mPPH). Ethylene was fed to the reactor at a rate such that its partial pressure in the reactor was still 1.52 megapascal (i.e. 220 psi). The polymer production rate was about 13.05 kilograms / hour (i.e., about 29 PPH). The reactor was equipped with a pressurizing device set to a power of about 436.5 kilograms / hour (i.e., about 970 PPH) of recycle gas (said pressurizing device being used in a recycle gas). «* ·

9 A gas-phase fluidized bed polymerization reactor to form a polymer particle-free zone). A 0.14 centimeter (i.e., 0.055 inch) inner diameter nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1 weight percent Catalyst B in hexane was stirred for about 15 minutes in a 0.48 centimeter (i.e. 3/16 inches) with hexene, which was 0.09 kilograms / hour (i.e., 0.2 lb / hour). The resulting mixture of Catalyst B and hexene was mixed directly with the cocatalyst (MMAO-3A containing 1 weight percent aluminum) on the production line for about 20-25 minutes. In a separate stainless steel activation tube, the toluene solution containing the weight percent of catalyst A was activated for about 50 to 55 minutes with the co-catalyst MMAO-3A. The two independently activated solutions were stirred together for 4 minutes to form a single process catalyst stream. The amount of catalyst A in the feed solution was approximately 40 to 45 mol percent. In addition, isopentane and nitrogen were fed to the solution to control the average particle size of the resulting polymer. The whole system passed through the feed nozzle into the fluidized bed. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 300: 1. This gave a bimodal polymer having a melt index of 0.054 g / 10 min and 7.94 g / 10 min and a density of 0.948 g / cm 2, respectively.³. The residual zirconium content of 1.1 ppmw was calculated based on the mass balance of the reactor. SEC analysis and deconvolution were performed using seven to eight powder distributions, the results of which are shown in Table I.

100 • · · · * · ♦ • · · · * · ·· * ·♦ ····

Example Section I-Example 5

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) diameter operating at 85 ° C, 2.2 megapascal (320 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 27.2 kilograms / hour (i.e., about 60 lb / hour), and hexene was fed to the reactor at a rate of about 0.36 kilograms / hour (i.e. 0.8 lb / hr) and hydrogen was fed to the reactor at a rate of 5.85 g / hr (i.e.

mPPH). Ethylene was fed to the reactor at a rate such that its partial pressure in the reactor was still 1.52 megapascal (i.e. 220 psi). The polymer production rate was approximately

15.3 kilograms / hour (i.e. approximately 34 PPH). The reactor was equipped with an overpressure device set at about 432 kilograms / hour (i.e. about 960 PPH) of recycle gas (the overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-free zone). A 0.14 centimeter (i.e., 0.055 inch) inner diameter nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1 weight percent Catalyst B in hexane was stirred for approximately 15 minutes in a 0.48 centimeter (i.e., 3/16 inch) stainless steel tube with 0.09 kg / hour (i.e. 2 lb / hour). The resulting mixture of Catalyst B and hexene was mixed directly with the cocatalyst (MMA0-3A containing 1 weight percent aluminum) on the production line for approximately 20-25 minutes. In a separate stainless steel activation tube was a toluene solution containing

101

<img file="CZ20021402A3_D0033.tif" />

9 • 9 9

9

9% by weight of catalyst A activated for approximately 50 to 55 minutes by the co-catalyst MMAO-3A. The two independently activated solutions were stirred together for 4 minutes to form a single process catalyst stream. The amount of Catalyst A in the feed solution was about 40 to 45 mole percent. In addition, isopentane and nitrogen were fed to the solution to control the average particle size of the resulting polymer. The whole system passed through the feed nozzle into the fluidized bed. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 300: 1. A bimodal polymer having a melt index of 0.077 grams / 10 minutes and 12.7 grams / 10 minutes and a density of 0.9487 grams / cm was obtained.³. The residual zirconium content of 0.9 ppmw was calculated based on the mass balance of the reactor. SEC analysis and deconvolution were performed using seven to eight powder distributions, the results of which are shown in Table I.

Example section I-example 6

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) diameter operating at 85 ° C, 2.2 megapascal (320 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 27.2 kilograms / hour (i.e., about 60 lb / hour), and hexene was fed to the reactor at a rate of about 0.36 kilograms / hour (i.e. 0.8 lb / hr) and hydrogen was fed to the reactor at a rate of 5.85 g / hr (i.e.

mPPH). Ethylene was fed into the reactor at such a rate that

102

<td> 4 ····</td><td> • 4</td><td colspan="2"> 4 44 4</td><td colspan="2"> • 4</td><td colspan="2"> 44</td>

<td> • 4 4</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td> •</td>

<td> • 4</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td></td><td> 4</td>

<td></td><td></td><td></td><td></td><td></td><td></td><td> 4</td><td></td>

<td> • 4</td><td> «</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td> 4</td><td></td>

<td> 444 4</td><td> • 4</td><td></td><td> 4</td><td></td><td> • 4</td><td> • •4</td><td> 4</td>

so that its partial pressure in the reactor was still 1.52 megapascal (i.e. 220 psi). The polymer production rate was approximately

15.3 kilograms / hour (i.e. approximately 34 PPH). The reactor was equipped with a pressurizing device set at about 495 kilograms / hour (i.e., about 1100 PPH) of recycle gas (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-free zone). A 0.14 centimeter (i.e., 0.055 inch) inner diameter nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1 weight percent Catalyst B in hexane was stirred for approximately 15 minutes in a 0.48 centimeter (i.e., 3/16 inch) stainless steel tube with 0.09 kg / hour (i.e. 2 lb / hour). The resulting mixture of Catalyst B and hexene was mixed directly with the cocatalyst (MMAO-3A containing 1 weight percent aluminum) on the production line for about 10-15 minutes. A toluene solution containing 1 weight percent of catalyst A was added to the activated catalyst B solution about 5 minutes before injection into the reactor. The amount of Catalyst A in the feed solution was about 40 to 45 mole percent. In addition, isopentane and nitrogen were fed to the solution to control the average particle size of the resulting polymer. The whole system passed through the injection nozzle into the fluidized bed. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 300: 1. A bimodal polymer having a melt flow index of 0.136 grams / 10 minutes and 38.1 grams / 10 minutes and a density of 0.9488 grams / cm was obtained.³. The residual zirconium content was

103

<td rowspan="2">&lt;to ··· • · • ·</td><td rowspan="2">to · «this · • · · to · »</td><td colspan="2">• it</td><td rowspan="2">it· •</td>

<td>• it</td><td> • •</td>

<td> • ·</td><td>this·</td><td> •</td><td> •</td><td> •</td>

<td>• do it</td><td>* · It</td><td></td><td> »·</td><td>• this</td>

0.5 ppmw, was calculated based on the mass balance of the reactor. SEC analysis and deconvolution were performed using seven to eight powder distributions, the results of which are shown in Table I.

Example section I-example 7

Ethylene / hexene was prepared in a 35.6 centimeter (14 inch) gas phase polymerization reactor operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 19.1 kilograms / hour (i.e., about 42 lbs / hour), hexene was fed into the reactor at a rate of about 0.36 kilograms / hour (i.e. 0.8 lb / hr) and hydrogen was fed to the reactor at a rate of 5.85 g / hr (i.e. 13 mPPH). Ethylene was fed to the reactor at a rate such that its partial pressure in the reactor was still 1.52 megapascal (i.e. 220 psi). The polymer production rate was about 14.4 kilograms / hour (i.e., about 32 PPH). The reactor was equipped with an overpressure device set at a power of approximately 904.5 kilograms / hour (i.e. approximately 2010 PPH) of recycle gas (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone). Conical nozzle with an inner diameter of 0.14 centimeters (i.e.

0.055 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 0.25 weight percent of Catalyst B in hexane was mixed with hexene in a 0.48 centimeter (i.e., 3/16 inch) diameter tube in a 0.48 centimeter diameter tube.

104

<img file="CZ20021402A3_D0034.tif" />

0.05 kilogram / hour (i.e. 0.1 lb / hour). The resulting mixture of Catalyst B and hexene was mixed directly with the cocatalyst (MMAO-3A containing 1 weight percent aluminum) on the production line for approximately 15 minutes. A toluene solution containing 0.5% by weight of catalyst A was added to the activated catalyst B solution approximately 15 minutes before being injected into the reactor. The amount of Catalyst A in the feed solution was about 65 to 70 mole percent. In addition, isopentane and nitrogen were fed to the solution to control the average particle size of the resulting polymer. The whole system passed through the feed nozzle into the fluidized bed. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 500: 1. A bimodal polymer having a melt index of 0.06 grams / 10 minutes and 6.26 grams / 10 minutes and a density of 0.905 grams / cm was obtained.³. The residual zirconium content of 0.65 ppmw was calculated based on the mass balance of the reactor. SEC analysis and deconvolution were performed using seven to eight powder distributions, the results of which are shown in Table I.

105 • ti

Table I

<td>Example</td><td>1 (compare)</td><td>2 (compare)</td><td> 3</td><td> 4</td><td> 5</td><td> 6</td><td> 7</td>

<td>I21 (g / 10min)</td><td> 0,28</td><td>on</td><td> 7,5</td><td> 7,94</td><td> 12,6</td><td> 38,1</td><td> 6,26</td>

<td>I21 / I2</td><td> —</td><td> —</td><td> 165,3</td><td> 147</td><td> 164,6</td><td> 280,4</td><td> 104</td>

<td>AND₂ (g / 10 min)</td><td>without flow</td><td> 797</td><td> 0,045</td><td> 0,054</td><td> 0,077</td><td> 0,136</td><td> 0,060</td>

<td colspan="8">Experimental data SEC</td>

<td>M_n</td><td> 80600</td><td> 2952</td><td> 7908</td><td> 10896</td><td> 10778</td><td> 10282</td><td> 8700</td>

<td>M_w</td><td> 407375</td><td> 13398</td><td> 340011</td><td> 263839</td><td> 259389</td><td> 261138</td><td> 287961</td>

<td>M_w/ M_n</td><td> 5,05</td><td> 4,54</td><td> 43</td><td> 24,2</td><td> 24,1</td><td> 25,4</td><td> 33,10</td>

<td>M_n (off)</td><td> —</td><td> —</td><td> 7645</td><td> 10552</td><td> 10673</td><td> 10105</td><td> 8523</td>

<td>M '(off)</td><td> —</td><td> —</td><td> 339752</td><td> 258282</td><td> 248215</td><td> 252310</td><td> 284814</td>

<td>M '/ M_n (off)</td><td> —</td><td> —</td><td> 44,44</td><td> 24,48</td><td> 23,26</td><td> 24,97</td><td> 33,42</td>

<td>LMW¹ M_n (off)</td><td> —</td><td> 2988</td><td> 3741</td><td> 5548</td><td> 5731</td><td> 6382</td><td> 4165</td>

<td>LMW¹ M_w (off)</td><td> —</td><td> 13214</td><td> 13259</td><td> 16388</td><td> 15214</td><td> 18333</td><td> 11771</td>

<td>LMW¹ M_w/ M_n(off)</td><td> —</td><td> 4,42</td><td> 3,54</td><td> 2,95</td><td> 2,65</td><td> 2,87</td><td> 2,83</td>

<td>HMW² M_n (off)</td><td> 73979</td><td> —</td><td> 122758</td><td> 111256</td><td> 85461</td><td> 88374</td><td> 115954</td>

<td>HMW² M_w (off)</td><td> 407513</td><td> —</td><td> 633154</td><td> 501013</td><td> 484657</td><td> 607625</td><td> 526630</td>

<td>HMW² M_w/ M_n(off)</td><td> 5,51</td><td> —</td><td> 5,16</td><td> 4,50</td><td> 5, 67</td><td> 6,88</td><td> 4,54</td>

<td>Share (HMW²/ total)</td><td> 100,00</td><td> 0,00</td><td> 52,67</td><td> 49, 92</td><td> 49, 64</td><td> 39,70</td><td> 53,03</td>

• 4 · « • 4 • ·

4

106

Table I - Completion

<td colspan="8">Reactor conditions</td>

<td>Example</td><td>1 (compare)</td><td>2 (compare)</td><td> 3</td><td> 4</td><td> 5</td><td> 6</td><td> 7</td>

<td>Temperature (° C)</td><td> 85</td><td> 80</td><td> 80</td><td> 85</td><td> 85</td><td> 85</td><td> 85</td>

<td>Pressure C₂³ (MPa (dogs))</td><td> 1,52 (220)</td><td> 1,24 (180)</td><td> 1,52 (220)</td><td> 1,52 (220)</td><td> 1,52 (220)</td><td> 1,52 (220)</td><td> 1,52 (220)</td>

<td>Molar ratio h₂/C₂³</td><td> 0,0016</td><td> 0,0018</td><td> 0,0013</td><td> 0,0014</td><td> 0,0014</td><td> 0,0010</td><td> 0,0019</td>

<td>Molar ratio C₆⁴/C₂³</td><td> 0,00488</td><td> 0,00153</td><td> 0,0074</td><td> 0,0073</td><td> 0,0077</td><td> 0,0075</td><td> 0,0050</td>

<td>Delay (throw.)</td><td> 3, 6</td><td> 7,5</td><td> 5,3</td><td> 4,74</td><td> 3,87</td><td> 3,87</td><td> 3,4</td>

<td>Molar ratio HMW²/ LMW^x</td><td> —</td><td> —</td><td> 0,71</td><td> 0,73</td><td> 0,76</td><td> 0,76</td><td> 2,16</td>

<td>Molar% Cat. A</td><td> 100</td><td> —</td><td> 41</td><td> 42</td><td> 43</td><td> 43</td><td> 68</td>

<td>Zr content according to Labs (ppm)</td><td> —</td><td> --</td><td> 1,33</td><td> 1,61</td><td> 1,33</td><td>WHAT O</td><td> 0, 97</td>

<td>Zr content according to Injection (ppm)</td><td> 1,63</td><td> —</td><td> 1,46</td><td> 1,06</td><td> 0,9</td><td> 0,54</td><td> 0,62</td>

<td>Diameter</td><td> 1,63</td><td> —</td><td> 1,40</td><td> 1,34</td><td> 1,12</td><td> 0,67</td><td> 0,80</td>

<td>Molar ratio Al / Zr</td><td> 400</td><td> —</td><td> 330</td><td> 380</td><td> 320</td><td> 307</td><td> 500</td>

<td>Activity Cat. B⁵</td><td> —</td><td> —</td><td> 9965</td><td> 12515</td><td> 18754</td><td> 37288</td><td> 50142</td>

<td>Activity Cat. A⁶</td><td> 15559</td><td> —</td><td> 15730</td><td> 17042</td><td> 24323</td><td> 32465</td><td> 26203</td>

ti ··· • · · ti

107 • ti ti ·· · ti ti ·· ····

Explanatory notes to the table:

¹ LMW = low molecular weight component ² HMW = high molecular weight component ³ C₂ = ethylene ⁴ C₆ = hexene ⁵' ⁶ indicated in grams of polyethylene / millimol catalyst / hour

Comparative Examples 1 and 2 of Example I illustrate how a one-component catalyst system behaves. Examples 3 and 4 how changes in temperature will occur if the other conditions in the reactor and the catalyst injection system are substantially the same. It should be noted that when using a higher temperature, the ratio of the polymer formed is M_w/ M_n as well as melt flow rate (MFR). Examples 5 and 6 served to compare the effect of different catalyst activation arrangements under otherwise substantially identical conditions in the reactor and catalyst system. In Example 6, the total catalyst activity was then found to be better. However, in this case, a smaller amount of high molecular weight material was formed. Examples 6 and 7 demonstrate the possibility of controlling the amount of high molecular weight material produced under substantially similar reactor conditions. In the case of Example 7, a higher amount of Catalyst A was injected into the reactor and accordingly a larger amount of higher molecular weight material was produced.

108

<img file="CZ20021402A3_D0035.tif" />

Example section I-example 8

159 kilograms (350 pounds) of polyethylene produced according to Example 4 (hereinafter referred to as polymer A) was mixed in a Werner-Fleiderer ZSK-30 twin screw extruder with a melt temperature of 220 ° C with 1000 ppm Irganox® 1076 and 1500 ppm

Irgafos® 1068 and the resulting mixture was formed into pellets. A 13 micron (0.5 mil) thick film was blown from the pellets on an Alpine foil extrusion line. The film was produced under the following extrusion conditions: a triplex slit of 160 millimeters, a slit width of 1.5 millimeters, a slit temperature of 400 ° C, a blown film width of 122 centimeters (48 inches), a target melting point of 210 ° C (410 ° F) and extrusion rates of 144 kg / hr (310 lb / hr), 191 kg / hr (420 lb / hr) and 209 kg / hr (460 lb / hr). For comparison, Escorene® HD7755.10 (which is a commercially available product from Exxon Chemical Company Houston, Texas, USA, manufactured in a series of reactors) was treated under the same conditions. All films were aged for 40 hours at 23 ° C and 50% humidity. The properties of each film are summarized in Table IA.

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110 * · 9 9 9 9 · (((· 9 9 9 9

Table ΙΑ - Completion

<td>HD7755.10</td><td> 108 (15609)</td><td> 79 (11482)</td><td> 299</td><td> 377</td><td> 60,9</td><td> 11,9</td>

<td>Polymer A</td><td> 89 (12934)</td><td> 81 (11727)</td><td> 253</td><td> 340 -1</td><td> 56, 9</td><td>cn I — I</td>

<td>HD7755.10</td><td> 104 (15110)</td><td> 85 (12278)</td><td> 296</td><td> 377</td><td>O OJ</td><td> 12,0</td>

<td>Polymer A</td><td> 87 (12574)</td><td> 74 (10785)</td><td> 246</td><td> 305</td><td>what Γ- ιο</td><td> 13, 4</td>

<td>HD7755.10</td><td> 99 (14347)</td><td> 84 (12124)</td><td> 293</td><td> 393</td><td>O uo</td><td> 10,8</td>

<td>Polymer A</td><td> 1 100 (14445)</td><td> 92 (13369)</td><td> 285</td><td> 317</td><td>cr LO</td><td> 13, 6</td>

<td></td><td>MD limit strength (MPa (psi))⁷</td><td>TD limit strength (MPa (psi))⁸</td><td>Ultimate elongation (%)</td><td>Ultimate elongation (%)</td><td>Turbidity (%)</td><td>45 ° gloss</td>

<td colspan="5"></td><td colspan="3">Φ</td>

<td></td><td></td><td></td><td></td><td>ω</td><td> &gt;</td><td></td><td></td>

<td></td><td></td><td></td><td></td><td>Η</td><td></td><td></td><td></td>

<td></td><td></td><td></td><td></td><td></td><td>Φ</td><td></td><td></td>

<td></td><td></td><td></td><td></td><td></td><td>ο</td><td></td><td></td>

<td></td><td></td><td></td><td></td><td>Φ</td><td>φ</td><td></td><td></td>

<td></td><td></td><td></td><td></td><td>Φ</td><td>ε</td><td></td><td></td>

<td></td><td></td><td></td><td></td><td>&gt; Φ</td><td>φ</td><td></td><td></td>

<td></td><td></td><td> 0</td><td>Φ</td><td>ε</td><td>ο</td><td></td><td></td>

<td></td><td></td><td>Η</td><td>• Η</td><td>φ</td><td>and</td><td></td><td></td>

<td></td><td> .—.</td><td>ι — 1</td><td>ι — 1</td><td></td><td>φ</td><td></td><td></td>

<td></td><td>Ή</td><td>Ό</td><td>Ό</td><td>ε</td><td>Ό</td><td></td><td></td>

<td></td><td>Φ</td><td>and</td><td>and</td><td>'φ</td><td>ι</td><td></td><td></td>

<td></td><td>ω</td><td></td><td></td><td>φ</td><td>Ή</td><td></td><td></td>

<td></td><td>Ν</td><td>Ή</td><td>χφ</td><td>&gt; υ</td><td>and</td><td></td><td>Ω</td>

<td></td><td>Ή</td><td>Φ</td><td>Φ</td><td></td><td>&gt; φ</td><td></td><td>Η</td>

<td></td><td>&gt; Φ</td><td>Ο</td><td>Φ</td><td>&gt; φ</td><td>and</td><td></td><td></td>

<td></td><td>Φ</td><td> 15</td><td>b</td><td>and</td><td>φ</td><td></td><td></td>

<td></td><td>Ν</td><td> 0</td><td>Ο</td><td></td><td>φ</td><td></td><td>Φ</td>

<td></td><td></td><td>Μ</td><td>Μ</td><td> &gt;</td><td></td><td></td><td>Φ</td>

<td></td><td>Φ</td><td>5-ι</td><td>5φ</td><td></td><td> 5-1</td><td></td><td>&gt; Φ</td>

<td></td><td>&gt; Φ</td><td> &gt;</td><td> &gt;</td><td></td><td>b</td><td></td><td>ε</td>

<td></td><td>WITH</td><td></td><td></td><td></td><td> &gt;</td><td></td><td>φ</td>

<td></td><td>Φ</td><td>η</td><td>Ό</td><td>α</td><td>-Η</td><td></td><td></td>

<td></td><td></td><td>Ο</td><td>Ο</td><td> £</td><td>&gt; φ</td><td></td><td>ε</td>

<td></td><td>Φ</td><td></td><td></td><td></td><td>b</td><td></td><td>'Φ</td>

<td></td><td>C</td><td> 0</td><td>Φ</td><td></td><td></td><td></td><td>φ</td>

<td></td><td></td><td>ο</td><td>Φ</td><td>Ή</td><td>φ</td><td></td><td>&gt; ο</td>

<td></td><td>ο</td><td>Ό</td><td>Ό</td><td>Φ</td><td>φ</td><td></td><td>Ή</td>

<td></td><td>WITH</td><td></td><td></td><td>Φ</td><td> &gt;0</td><td></td><td>&gt; φ</td>

<td></td><td> 1—1</td><td></td><td> &lt;</td><td>Ν</td><td>φ</td><td></td><td>and</td>

<td></td><td>ο</td><td>and</td><td>Γ—</td><td>χφ</td><td>φ</td><td></td><td></td>

<td></td><td>b</td><td></td><td></td><td>&gt; Φ</td><td></td><td></td><td> &gt;</td>

<td></td><td></td><td>ε</td><td>ε</td><td>Φ</td><td>ο</td><td></td><td></td>

<td></td><td> •</td><td>ο</td><td>φ</td><td>Ν</td><td>b</td><td></td><td></td>

<td></td><td>• π</td><td>and</td><td>and</td><td></td><td>φ</td><td></td><td>X.</td>

<td></td><td>and</td><td>χφ</td><td>Ή</td><td>Φ</td><td>η</td><td></td><td>Ω</td>

<td></td><td> —·</td><td>&gt; Φ</td><td>&gt; ω</td><td>Φ</td><td></td><td></td><td> £</td>

<td></td><td></td><td></td><td></td><td>&gt; Φ</td><td>5-ι</td><td></td><td></td>

<td></td><td> 0</td><td>ε</td><td>ε</td><td>ε</td><td>Φ</td><td></td><td></td>

<td></td><td>Φ</td><td>χφ</td><td>χφ</td><td>φ</td><td>Φ</td><td></td><td>χφ</td>

<td></td><td>&gt; φ</td><td>ο</td><td>Ο</td><td></td><td>ί&gt;</td><td></td><td>φ</td>

<td></td><td>ε</td><td>Ή</td><td>Ή</td><td>φ</td><td>Ο</td><td>Φ</td><td>φ</td>

<td></td><td>φ</td><td>• π</td><td>-ΓΊ</td><td> &gt;</td><td>Φ</td><td>Φ</td><td>Ν</td>

<td></td><td></td><td>Φ</td><td>Φ</td><td></td><td>Φ</td><td>&gt; Φ</td><td>χφ</td>

<td></td><td>WITH</td><td>Ό</td><td>Ό</td><td>and</td><td>and</td><td>ε</td><td>&gt; Φ</td>

<td></td><td>'Φ</td><td>Φ</td><td>Φ</td><td>Μ</td><td>φ</td><td>φ</td><td>Φ</td>

<td></td><td></td><td>and</td><td>and</td><td> 0</td><td></td><td></td><td>Ν</td>

<td></td><td>&gt; υ</td><td></td><td></td><td>Ό</td><td>• Η</td><td>ε</td><td></td>

<td></td><td>χφ</td><td>'Φ</td><td>'Φ</td><td>φ</td><td>and</td><td>'Φ</td><td>Φ</td>

<td></td><td>&gt; Φ</td><td>Φ</td><td>φ</td><td>φ</td><td>φ</td><td>φ</td><td>Φ</td>

<td></td><td>and</td><td>φ</td><td>φ</td><td>ε</td><td>ο</td><td>&gt; υ</td><td>&gt; Φ</td>

<td></td><td></td><td> &gt;</td><td> &gt;</td><td>Γ— |</td><td>φ</td><td>'Ή</td><td>ε</td>

<td></td><td> &gt;</td><td> 0</td><td>ο</td><td>ω</td><td>&gt; Ν</td><td>&gt; φ</td><td>φ</td>

<td></td><td></td><td> 4-)</td><td>and</td><td></td><td>Φ</td><td>and</td><td></td>

<td></td><td>II</td><td>Φ</td><td>φ</td><td>χφ</td><td>Φ</td><td></td><td>φ</td>

<td></td><td></td><td>Φ</td><td>φ</td><td>Φ</td><td>and</td><td> &gt;</td><td> &gt;</td>

<td></td><td>Ω</td><td>and</td><td>and</td><td>Φ</td><td></td><td></td><td></td>

<td></td><td>Βη</td><td></td><td></td><td>&gt; Ν</td><td>and</td><td></td><td>φ</td>

<td></td><td></td><td> 4-&gt;</td><td>and</td><td> 44</td><td>Φ</td><td></td><td>b</td>

<td></td><td> »*.</td><td>φ</td><td>φ</td><td>and</td><td>Ό</td><td>α</td><td>φ</td>

<td> . </td><td>Ή</td><td>ο</td><td> 0</td><td>ο</td><td>Ο</td><td> £</td><td>and</td>

<td>O</td><td> 0</td><td>and</td><td>and</td><td>Ό</td><td>ε</td><td></td><td></td>

<td>O</td><td>ο</td><td>φ</td><td>φ</td><td></td><td></td><td></td><td> &gt;</td>

<td> &lt;—1</td><td>Ν</td><td>ο</td><td>φ</td><td>• Η</td><td> •</td><td>χφ</td><td></td>

<td> 0</td><td>χφ</td><td> &gt;</td><td> &gt;</td><td>and</td><td>η</td><td>φ</td><td>and</td>

<td>ti</td><td>&gt; Φ</td><td>φ</td><td>φ</td><td>ο</td><td>and</td><td>φ</td><td>φ</td>

<td> (0</td><td>ο</td><td>&gt; Ν</td><td>&gt; Ν</td><td>φ</td><td></td><td>Ν</td><td>ο</td>

<td>and</td><td>Ν</td><td>Φ</td><td>Φ</td><td>and</td><td></td><td>χφ</td><td>φ</td>

<td></td><td></td><td>ο</td><td>Ο</td><td></td><td>and</td><td>&gt; Φ</td><td> &gt;</td>

<td>b</td><td> 0</td><td>b</td><td>b</td><td>and</td><td>φ</td><td>Φ</td><td>φ</td>

<td></td><td>Φ</td><td></td><td></td><td>φ</td><td>φ</td><td>Ν</td><td>and</td>

<td> &gt;1</td><td>&gt; Φ</td><td>'Φ</td><td>'Φ</td><td> 0</td><td>b</td><td></td><td></td>

<td>b</td><td>ε</td><td> &gt;</td><td> &gt;</td><td>φ</td><td>Φ</td><td>Φ</td><td>Ή</td>

<td> &gt;</td><td>ο</td><td>ο</td><td>Ο</td><td>Γ-Η</td><td>φ</td><td>Φ</td><td> £</td>

<td>• Φ</td><td></td><td>Ν</td><td>Ν</td><td>ο</td><td></td><td>&gt; Φ</td><td>Ν</td>

<td>i — 1</td><td>αί</td><td>'Φ</td><td>'Φ</td><td>Ό</td><td>θ \ °</td><td>ε</td><td>(D</td>

<td>and</td><td> &gt;</td><td>ck</td><td>(X</td><td>Ο</td><td>and</td><td>φ</td><td> £</td>

<td>&gt; Φ</td><td></td><td></td><td></td><td></td><td></td><td></td><td></td>

<td> &gt;</td><td>II</td><td></td><td></td><td></td><td></td><td></td><td></td>

<td>φ</td><td></td><td></td><td></td><td> *3*</td><td>ΙΏ</td><td></td><td> 00</td>

<td> 5-1</td><td>α</td><td></td><td></td><td></td><td></td><td></td><td></td>

<td> &gt;</td><td> £</td><td>r-1</td><td> 03</td><td>η</td><td>ιΠ</td><td></td><td>Γ-</td>

00 * «

: · · 0 ·

111

0· ·

0· ·0 0 0 0 *

0 ·

0»

0 0 « 0 0 0 0 0

Escorene HD7755.10 is a linear polyethylene polymer manufactured using a dual reactor system, commercially available from Exxon Chemical Company, Houston, Texas, USA. Melt flow index value₂this polymer is 7.5, the melt index (MIR) is 125, the weight average molecular weight of the polymer is 180000, and its density is 0.95 grams / cm³.

Example section I-example 9

Several barrels of granulate samples (produced by the polymerization method described above using a mixture of catalysts A and B in a ratio of 2.3 (A: B)) were mixed in a drum with 1000 ppm Irganox® 107.6, 1500 ppm Irgafos® 1068 and 1500 ppm calcium stearate . The resulting mixture was pelletized at 204 ° C (400 ° F) on a Prodex line with the resulting pellets having a size of

6.35 centimeters (2.5 ”). Foil was extruded from the pellets produced in the Alpine foil blowing line with a single screw having a diameter of 50 millimeters, a length to diameter extruder (L / D) of 18: 1, and a line having a 100 mm annular gap. the width was 1 millimeter. Extrusion was performed under the following conditions: slot temperature 204 ° C (400 ° F), line performance was 46 kilograms / hour (100 lbs / hour). A typical temperature profile was as follows:

193 C ° C / 204 C ° C / 204 C ° C / 204 C ° C / 204 C ° C / 204 C ° C / 210 C ° C / 210 C ° C (380 C / 400 C / 400 C / 400 C / 400 C / 400 C ° C (400 ° C / 410 ° C / 410 ° C) for the drum / drum2 / block adapter / bottom adapter / vertical adapter / slot bottom / slot center / slot top. The pellet samples were extruded to form a 25 micron (1.0 mil) sheet at a line speed of 48 centimeters.

9 9 9

Ά -L &lt;- 9 «9 9 ·

9 9 · 99 9 999999 second (92 fpm) and 13 micron (0.5 mil) thick film at a line speed of 94 centimeters / second (184 fpm) at a blow rate (BUR) of 4.0. In both cases, the resulting sleeve exhibited excellent stability with a typical constriction in the shape of a wine bottle. The deflated sleeve line height (FLH) was maintained at 91.4 centimeters (36 inches) for the 25 micron (1.0 mil) sheet, and for the 12.5 micron (0.5 mil) sheet, this line was maintained at 101.6 centimeters (40 inches). The extrusion head pressure and engine load were slightly higher than when extruding Escorene® HD7755.10 (which is a commercially available product from Exxon Chemical Company Houston, Texas, USA, produced in a series of reactors) under the same extrusion conditions. The properties of the resulting films are summarized in Table IB. All films were aged for 40 hours at 23 ° C. The impact strength tested by a falling arrow of a 12.5 micron (0.5 mil) sheet was 380 grams, which is higher than the same film made from Escorene® HD7755.10, which was 330 grams.

Table IB

<td></td><td>Escorene® 7755</td><td>Polymer B</td>

<td>AND₂ (g / 10 minutes)</td><td> 0,08</td><td> 0,062</td>

<td>AND₂i (g / 10 minutes)</td><td> 10</td><td> 10,02</td>

<td>AND₂i / I₂</td><td> 134</td><td> 160,5</td>

<td>Density (g / cm^J)</td><td> 0,952</td><td> 0,9485</td>

<td>Output (kg / h (lb / h))</td><td> 47 (100)</td><td> 104 (47)</td>

113

4 4 · · · · · · · ·

<img file="CZ20021402A3_D0036.tif" />

• · *·· 4 9« ♦1« ♦ 49 4 »♦·»·»

Table ΙΒ - continued

<td></td><td colspan="2">Escorene® 7755</td><td colspan="2">Polymer B</td>

<td>Slot flow (kg / hr) (lb / hr))</td><td> ~3, 6</td><td> (~8)</td><td> ~3, 6</td><td> (~8)</td>

<td>Pressure on extrusion head (MPa</td><td> 50</td><td></td><td> 53</td><td></td>

<td>(dogs))</td><td> (7200)</td><td></td><td> (7600)</td><td></td>

<td>Motor load (amp)</td><td> 56</td><td></td><td> 61</td><td></td>

<td>Blow ratio (BUR)</td><td> 4</td><td></td><td> 4</td><td></td>

<td>Setting line height (FLH)</td><td> 91,4</td><td> 101,6</td><td> 91,4</td><td> 101, 6</td>

<td>(cm (inch))</td><td> (36)</td><td> (40)</td><td> (36)</td><td> (40)</td>

<td>Melt fracture</td><td>No</td><td></td><td>No</td><td>No</td>

<td>Sleeve stability</td><td>Good</td><td></td><td>Good</td><td>Good</td>

<td>Extrusion speed (m / s)</td><td> 0,5</td><td> 0,9</td><td> 0,5</td><td> 0,9</td>

<td>(fpm))</td><td> (92)</td><td> (185)</td><td> (92)</td><td> (184)</td>

<td>Foil thickness</td><td> 25</td><td> 12,5</td><td> 25</td><td> 12,5</td>

<td>(pm)</td><td> (1)</td><td> (0,5)</td><td> (1)</td><td> (0,5)</td>

<td>Impact toughness (grams)</td><td> 250</td><td> 330</td><td> 290</td><td> 360</td>

<td colspan="5">Tensile strength (MPa (psi))</td>

<td>MD</td><td> 58 (8400)</td><td> 78 (11300)</td><td> 56 (8100)</td><td> 79 (11400)</td>

<td>TD</td><td> 55 (7900)</td><td> 72 (10400)</td><td> 50 (7230)</td><td> 66 (9520)</td>

<td colspan="2">Elongation (%)</td><td> )</td><td></td><td></td>

<td>MD</td><td> 350</td><td> 230</td><td> 410</td><td> 330</td>

<td>TD</td><td> 570</td><td> 390</td><td> 580</td><td> 410</td>

114 »-9 0 00 0 •

Table IB - completion

<td colspan="5">Elmendorf tear resistance (g / pm (g / mil))</td>

<td>MD</td><td> 0,98 (25)</td><td> 0,87 (22)</td><td> 0,95 (24)</td><td> 1,30 (33)</td>

<td>TD</td><td> 5,59 (142)</td><td> 2,83 (72)</td><td> 8,07 (205)</td><td> 2,80 (71)</td>

<td colspan="5">Modulus of elasticity (MPa (psi))</td>

<td>MD</td><td> 876 (127000)</td><td> 993 (144000)</td><td> 907 (131500)</td><td> 933 (135350)</td>

<td>TD</td><td> 1007 (146000)</td><td> 1165 (169000)</td><td> 1105 (160250)</td><td> 1078 (156300)</td>

Example section I-example 10

In the same manner as in Example 9, there were several barrels of granulate samples (polymer C produced by the above-described polymerization process using a 0.732 (A: B) mixture of catalysts A and B and polymer D produced by the above-described polymerization process using a mixture of catalysts A and B in 2.6 (A: B)) mixed in a drum with 1000 ppm Irganox® 1076, 1500 ppm Irgafos® 1068 and 1500 ppm calcium stearate. The resulting mixtures were pelletized and extruded as described in Example 9. All films were aged for 40 hours at 23 ° C. The impact strength tested by a falling arrow of a 12.5 micron (0.5 mil) film was 380 grams for both Polymer C and D films, which is higher than for the same Escorene film ® HD7755.10 when this parameter was 330 grams. The data are summarized in Table IC.

<img file="CZ20021402A3_D0037.tif" />

·»»* ·· *

115

Table IC

<td>Sample</td><td>Polymer C</td><td>Polymer D</td><td>Escorene® 7755</td>

<td>Reaction temperature (° C)</td><td> 85</td><td> 85</td><td></td>

<td>C₂ (kPa (psi)</td><td> 1517 (220)</td><td> 1517 (220)</td><td></td>

<td>Molar H ratio₂/C₂</td><td> 0,0014-0,0016</td><td> 0,0012</td><td></td>

<td>Molar ratio C₆/C₂</td><td> 0,0075-0,0078</td><td> 0,00531-0,00586</td><td></td>

<td>M_n</td><td> 14600</td><td> 16400</td><td></td>

<td>M "</td><td> 309100</td><td> 298200</td><td> 291500</td>

<td>M '/ M_n</td><td> 21,2</td><td> 18,2</td><td> 15,7</td>

<td>HMW / LMW</td><td> 53,8/46,2</td><td> 50,5/49,5</td><td></td>

<td>AND₂ (g / 10 min)</td><td> 0,056</td><td> 0,049</td><td> 0,08</td>

<td>I21 (g / 10 min)</td><td> 6,48</td><td> 6,7</td><td> 10</td>

<td>WI₂</td><td> 115,8</td><td> 138</td><td> 134</td>

<td>Density (g / cm³)</td><td> 0,9487</td><td> 0,9461</td><td> 0, 952</td>

<td>Performance (kg / hour) (lb / hr))</td><td> 46 (102)</td><td> 46 (102)</td><td> 45 (100)</td>

<td>Flow slit (kg / hour) (lb / hr))</td><td> ~3,6 (~8)</td><td> ~3., 6 (~8)</td><td> ~4,5 (~10)</td>

··♦*

116

Table IC - continued

<td></td><td colspan="2">Polymer C</td><td colspan="2">Polymer D</td><td colspan="2">Escorene® 7755</td>

<td>Pressure on extrusion head (MPa (dogs))</td><td colspan="2"> 56 (8120)</td><td colspan="2"> 54 (7890)</td><td colspan="2"> 50 (7230)</td>

<td>Load motor (amp)</td><td colspan="2"> 64,5</td><td colspan="2"> 63</td><td colspan="2"> 59</td>

<td>Blown ratio (BUR)</td><td colspan="2"> 4</td><td colspan="2"> 4</td><td colspan="2"> 4</td>

<td>Line height solidification (FLH) (cm (inch))</td><td> 101, 6 (40)</td><td> 101, 6 (40)</td><td> 91,4 (36)</td><td> 101, 6 (40)</td><td> 91,4 (36)</td><td> 101,6 (40)</td>

<td>Melt fracture</td><td colspan="2">No</td><td colspan="2">No</td><td colspan="2">No</td>

<td>Stability sleeve</td><td>uspoko- j ivá</td><td>Good</td><td>Good</td><td>Good</td><td>Good</td><td>Good</td>

<td>Thickness foil (pm)</td><td> 25,4 (1)</td><td> 12,7 (0,5)</td><td> 25,4 (1)</td><td> 12,7 (0,5)</td><td> 25,4 (1)</td><td> 12,7 (0,5)</td>

<td>Impact toughness (gramme)</td><td> 200</td><td> 380</td><td> 200</td><td> 380</td><td> 250</td><td> 330</td>

<td colspan="7">Tensile strength (MPa (psi))</td>

<td>MD</td><td> 71 (10300)</td><td> 137 ¢19900)</td><td> 68 (9900)</td><td> 107 (15500)</td><td> 58 (8400)</td><td> 78 (11300)</td>

<td>TD</td><td> 55 (7900)</td><td> 95 (13800)</td><td> 58 (8400)</td><td> 100 (14500)</td><td> 55 (7900)</td><td> 72 (10400)</td>

·· ·-»-·

<img file="CZ20021402A3_D0038.tif" />

117 • ti ti ti ti ti * ti titititi

Table IC - completion

<td></td><td colspan="2">Polymer C</td><td colspan="2">Polymer D</td><td colspan="2">Escorene® 7755</td>

<td colspan="7">Ductility (%)</td>

<td>MD</td><td> 320</td><td> 240</td><td> 290</td><td> 250</td><td> 350</td><td> 230</td>

<td>TD</td><td> 630</td><td> 385</td><td> 610</td><td> 350</td><td> 570</td><td> 390</td>

<td colspan="2">Resistant against</td><td colspan="3">Elmendorf retention (g / pm</td><td>(g / m))</td><td></td>

<td></td><td> 0, 95</td><td> 0,83</td><td> 1,42</td><td> 1,42</td><td> 0,98</td><td> 0,87</td>

<td>MD</td><td> (24)</td><td> (21)</td><td> (36)</td><td> (36)</td><td> (25)</td><td> (22)</td>

<td></td><td> 16,1</td><td> 3,4</td><td> 13,8</td><td> 2,6</td><td> 5,6</td><td> 2,8</td>

<td>TD</td><td> (410)</td><td> (87)</td><td> (350)</td><td> (66)</td><td> (142)</td><td> (72)</td>

<td></td><td colspan="3">Modulus of elasticity (MPa</td><td>(dogs))</td><td></td><td></td>

<td></td><td> 724</td><td> 827</td><td> 710</td><td> 758</td><td> 876</td><td> 993</td>

<td>MD</td><td> (105)</td><td> (120)</td><td> (103)</td><td> (110)</td><td> (127)</td><td> (144)</td>

<td></td><td> 883</td><td> 869</td><td> 889</td><td> 786</td><td> 1007</td><td> 1165</td>

<td>TD</td><td> (128)</td><td> (126)</td><td> (129)</td><td> (114)</td><td> (146)</td><td> (169)</td>

Alpine line, 5.1-inch (2-inch) diameter worm, 10.2-cm (4-inch) projection slot, 1016-micron (40-mile) slot width, 210 ° C (410 ° F) slot temperature.

The meaning of all abbreviations is the same as in the previous tables.

In addition to the examples described above, a group of other variants of the polymerization process using the catalyst systems described herein include the following:

♦ this · • ·· it

118

<img file="CZ20021402A3_D0039.tif" />

in ·· this • · &lt;·

I · to · to ·· ····

1. Compound I can be dissolved in a solvent, preferably toluene, to form a solution of the desired concentration, which can then be used with other catalyst systems.

2. Catalyst A may be used as a 0.50 weight percent solution in toluene, and Catalyst B may be used as a 0.25 weight percent solution in hexane, at a B to A molar ratio of about 0.7, when both catalysts are activated separately and then mixed together (so-called parallel activation) or in a B to A molar ratio of 2.2 to 1.5 when catalyst A is first activated and then catalyst B is added ( called gradual activation).

3. Increase or decrease the reaction temperature in order to narrow or expand the molecular weight distribution (M_w/ M_n) .

4. Change the residence time to affect product properties. Major changes can have a significant impact. A residence time of from 1 to 5, preferably 4 hours, seems sufficient to produce a product with good properties.

5. Spraying said catalyst into the reactor in such a way as to form a zone free of polymer particles. A polymer particle-poor zone can be formed at a circulating gas flow of 22500 kilograms / hour (50,000 pounds / hour) through a 15.24 centimeter (6 inch) diameter conduit. The catalyst can be atomized using a spray nozzle using nitrogen as the atomizing gas.

• • «to • ·· ·

119

6. The activating agent, preferably MMAO 3A, can be used as a 7% by weight solution in isopentane, hexane or heptane, the injection rate being sufficient to provide an Al / Zr ratio of from 100 to 300.

7. Catalyst A is mixed directly in the production line with MAO 3A, and then catalyst B is added directly to the resulting mixture directly on the production line. The entire mixture is then injected into the reactor.

8. Catalyst A is mixed directly with the MAO 3A in the production line, Catalyst B is also mixed directly with the MMAO 3A on the production line, the two activated catalysts are mixed together directly on the production line, and the entire mixture is subsequently injected into the reactor.

The examples in Example II describe the use of a catalyst system comprising a catalytic metal compound comprising a Group 15 element containing benzyl leaving groups.

Example section II. A mixed catalyst system comprising a metal catalyst comprising a Group 15 element of the Periodic Table of the Elements with benzyl leaving groups.

[(2,4,6-Me₃C6H2) NHCH₂CH 2] 2 was not (NH ligand) and {[(2,4,6Me₃C₆H₂) NCH₂CH₂] ₂NH} Zr (CH₂Ph) ₂ or (Zr-HN3) were prepared as described in Example I above.

120 • ·· · ·· ··*·

Preparation of {[(2,4,6-Me₃C₆H₂) NCH₂CH₂] ₂NH 3 ZrCl₂ or (ZrCl₂-HN3)

5.480 grams (20.48 millimoles) of Zr (NMe₂)₄ was dissolved in a 250 mL round bottom flask in 50 mL pentane. To the solution was added 6.656 g (20.48 millimoles) of [(2,4,6-Me₃C₆H₂) NHCH₂CH₂] ₂NH 3 as a solution in 50 mL of pentane and the resulting solution was stirred for 2 hours. Formation of mixed amide {[(2,4,6-Me₃C₆H₂) NCH₂CH₂] ₂NH} Zr (NMe₂) ₂ was detected by proton NMR, but this amide was not isolated from the mixture. ^X@ 1 H NMR₆Ds) δ 6.94 (m, 4), 3.33 (m, 2), 3.05 (s, 6), 3.00 (m, 2), 2.59 (m, 4), 2, 45 (s, 6), 2.43 (s, 6), 2.27 (s,

6), 2.20 (s, 6), 1.80 (m, 1). The solvent was removed in vacuo, the residue was dissolved in toluene and 6.0 grams (55 millimoles) of ClSiMe was added all at once.₃. The solution was stirred for 24 hours, the solvent was removed in vacuo and the solids were suspended in pentane, isolated by filtration and washed with pentane. 5.528 g (54 percent) of the desired dichloride was obtained, which was detected by proton NMR.

¹@ 1 H NMR₆D₆) δ 6.88 (s, 2), 6.81 (s, 2), 3.32 (m, 2), 2.86 (m, 2), 2.49 (s, 6), 2.47 (m, 4), 2.39 (s, 6), 2.12 (s, 6) the NH signal disappeared.

Preparation of Catalyst A (for Example II)

In a 100 ml round bottom flask, to 2.051 grams of methylalumoxane (MAO) (as 6.836 grams of 30 weight percent toluene solution, commercially available from Albermarle Corporation, Baton Rouge, Louisiana, USA) and 7.285 grams 0.145 g of ZrCl was added to toluene₂-HN3. The resulting solution was stirred for 15 minutes

121 5.070 grams of silica (Davison 948, annealed at 600 ° C, available from WR Grace, Davison Division, Baltimore, Maryland, USA) was added thereto, and the mixture was thoroughly mixed. The mixture was then dried in vacuo overnight to give 7.011 grams of a catalyst containing 0.36 weight percent zirconium with an Al / Zr ratio of 122: 1.

Preparation of Catalyst B (for the purpose of Example II)

In a 100 ml round bottom flask, 0.801 grams of methylalumoxane (MAO) (2.670 grams of 30 weight percent toluene solution, commercially available from Albermarle Corporation, Baton Rouge, Louisiana, USA) and 4.679 grams of toluene was added 0.070 grams of Zr-HN3. The resulting solution was stirred for 15 minutes and 2.130 grams of silica (Davison 948, calcined at 600 ° C) available from WR was added. Grace, Davison Division, Baltimore, Maryland, USA) and mixed thoroughly. The mixture was then dried in vacuo overnight to give 2.899 grams of a catalyst containing 0.35 weight percent zirconium with an Al / Zr ratio of 120: 1.

Example Section II-Comparative Example 1. Polymerization of ethylene in suspension using Catalyst A

The polymerization was carried out in a 1 liter slurry polymerization autoclave reactor equipped with a mechanical stirrer, an outer water jacket for temperature control, an inlet and outlet piping which

122 It was equipped with septa and a controlled supply of dry nitrogen and ethylene. The reactor was dried and de-aired at 160 ° C. Then 400 ml of isobutane, which served as solvent, was added to the reactor, and 0.7 ml of a 25 wt.% Solution of trioctyl aluminum in hexane, which was used as a scavenger, using an airtight syringe. The reactor was heated to 90 ° C, 0.200 grams of catalyst A was added thereto using compressed ethylene, and the reactor was pressurized with ethylene to a pressure of 986 kilopascals (i.e. 143 psi). The polymerization was run for 40 minutes at a constant ethylene flow rate of 90 ° C and a pressure of 986 kilopascals (143 psi). The reaction was quenched by rapid cooling and depressurization. 10.5 grams of polyethylene were obtained (FI = no melt flow, catalyst activity = 209 grams of polyethylene / millimole catalyst / hour).

Example Section II - Example 2. Slurry polymerization of ethylene using Catalyst B

The polymerization was carried out in a 1-liter slurry polymerization autoclave reactor equipped with a mechanical stirrer, an external water jacket for temperature control, a septum inlet and outlet line, and a controlled dry nitrogen and ethylene feed. The reactor was dried and de-aired at 160 ° C. Then 400 ml of isobutane, which served as solvent, was added to the reactor, and, using an airtight syringe, 0.7 ml of a 25 weight percent solution of trioctyl aluminum in hexane, which served as scavenger. The reactor was heated to 90 ° C and 0.100 grams was added thereto using compressed ethylene

123 ·«·· ·· • * • · · • · · • · · ·· · ·· ·· • « · ♦ • « * » · * · ·

9999 Catalyst A and the reactor was pressurized with ethylene to a pressure of 993 kilopascal (i.e. 144 psi). The polymerization was carried out for 30 minutes at a constant ethylene flow rate of 90 ° C and a pressure of 993 kilopascal (144 psi). The reaction was quenched by rapid cooling and depressurization. 11.8 grams of polyethylene were obtained (FI = no melt flow, catalyst activity 641 grams of polyethylene / millimol catalyst / hour).

From the above, it follows that, under similar reaction conditions, a catalytic metal compound containing a Group 15 element and a leaving group which is a substituted hydrocarbon, preferably an alkyl substituted by an aryl group, has a much higher activity than the same halogen containing compound.

The examples in Example III describe the use of a catalyst system comprising an aluminum activating agent bound to silica.

Example section III. A mixed catalyst system comprising an oxide-bound aluminum activating agent.

[(2,4,6-Me₃C6H₂) NHCH₂CH₂] ₂ or (ligand) and {[(2,4,6Me₃C₆H₂(NCH 2 CH 2] 2 NH 2 Zr (CH₂Ph) ₂ or (Zr-HN3) were prepared as described in Example I above.

Preparation of aluminum bound to silica (Si - O - Al (CgF₅) ₂)

A sample of 40.686 grams of silica (Davison 948, annealed at 600 ° C and available from WR Grace, Davison Division, Baltimore, Maryland, USA) was suspended in ·· ··· * • to ··

124 ♦ to ··

<img file="CZ20021402A3_D0040.tif" />

500 ml round-bottomed flask in 300 ml toluene. To the suspension was added 15.470 grams (24.90 millimoles) of solid A1 (C₆F₅)₃ as a solvate with one molecule of toluene and the resulting mixture was stirred for 30 minutes. The mixture was allowed to stand for 18 hours and the silica bound aluminum was collected by filtration and dried under vacuum for 6 hours to give 49.211 grams of product. Al (C₆F₅) ₃Toluene was obtained as described in European Patent Application Publication No. EP 0 694 548, the contents of which are incorporated herein by reference.

Preparation of Catalyst A (for the purpose of Example III)

To a suspension of 1.000 g of silica-bound aluminum (prepared in the above example) in 20 ml of toluene was added 0.076 g (0.124 mmol) of Zr-HN3 in 5 ml of toluene. The mixture was stirred for 30 minutes. The silica, which was colorless, turned orange-red. The silica was then isolated by filtration and dried under vacuum for 6 hours to give 1.051 g of product. The resulting transition metal concentration was 116 micromoles / gram catalyst.

Example Section III-Example 1. Polymerization of ethylene and hexene in suspension using Catalyst A

The polymerization was carried out in a 1-liter slurry polymerization autoclave reactor equipped with a mechanical stirrer, an outer water jacket for temperature control, a septum-supplied inlet and outlet line, and a controlled dry nitrogen inlet;

125 • fe ··· &lt;· ♦ · · · · «« ««

<img file="CZ20021402A3_D0041.tif" />

Ethylene. The reactor was dried and de-aired at 160 ° C. 400 ml of isobutane solvent, 35 ml of 1-hexene were added to the reactor, and 0.7 ml of a weight percent solution of trioctyl aluminum in hexane was used as a scavenger using an airtight syringe. The reactor was heated to 60 ° C, 0.100 grams of catalyst 3A was added thereto, and the reactor was pressurized with ethylene to a pressure of 538 kilopascals (i.e. 78 psi). The polymerization was continued for 30 minutes at a constant ethylene flow rate of 60 ° C and a pressure of 538 kilopascals (78 psi). The reaction was quenched by rapid cooling and depressurization.

70.0 grams of copolymers were obtained (FI = no melt flow, catalyst activity = 2320 grams of polyethylene / millimol catalyst / hour, 10.5 weight percent of 1-hexene was incorporated into the copolymer structure).

The examples in Example IV describe the use of injecting a solution of a catalytic metal compound containing a Group 15 element.

Example section IV. Injection of a solution of a catalytic metal compound containing a Group 15 element.

[(2,4,6-Me₃C₆H₂) NHCH₂CH₂] 2 or (NH ligand or precursor of compound I) and {[(2,4,6-Me₃C₆H₂) NCH₂CH₂] ₂NH} Zr (CH₂Ph) ₂ or (compound I) were prepared by the procedures described in Example I above.

126 • ···· ·· ···· ·» ·· ·· ··· ····?

• a · &lt;&lt; · ·· * ti ti ti ti ti ti ti ti ti ti ti ti ti

Preparation of Catalyst A (for the purposes of Example Section IV) A 1.5 percent catalyst solution in toluene was prepared by the following step sequence, all operations being carried out in a dry box.

100 grams of purified toluene were weighed into a 1 liter Erlenmeyer flask equipped with a Teflon coated stirrer. 7.28 grams of tetrabenzyl zirconium was added to the toluene and the resulting solution was allowed to stir for 5 minutes, during which time all the solid dissolved. To the solution was added 5.42 grams of compound I and an additional 551 grams of purified toluene. The mixture was allowed to stir for 15 minutes, again dissolving all solids. The resulting catalyst solution was transferred to a clean 1 liter Whitey cylinder, which was subsequently labeled, removed from the dry box, and placed in a holder where it was ready for later use.

Example Section IV - Example 1

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lbs / hour), hexene was fed into the reactor at a rate of about 0.3 kilograms / hour (i.e. 0.6 lb / hr) and hydrogen was fed to the reactor at a rate

2.25 g / hour (i.e., 5 mPPH). It was further fed into the reactor

127 • ·

<img file="CZ20021402A3_D0042.tif" />

as a supplementary gas nitrogen at a rate of 2.25 to

3.6 kilograms / hour (i.e. 5-8 PPH). The polymer production rate was about 12.15 kilograms / hour (i.e., about 27 PPH). The reactor was equipped with an overpressure device set at 855 kilograms / hour (i.e. 1900 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone. Learn more about using this type of device. can be found in U.S. Patent No. 5,693,727). A 0.11 centimeter (i.e., 0.041 inch) inner diameter conical nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1% by weight of catalyst A in toluene and a cocatalyst (a solution of ΜΜΆΟ-3Α in hexane containing 1% by weight of aluminum (MMAO-3A is a solution of modified methylalumoxane in heptane, commercially available from Akzo Chemicals, Inc. under the trade name Modified) Methylaium oxane type 3A)) were mixed directly on the production line before being injected into the fluidized bed using said nozzle. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 400: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂1 was 0.28 grams / 10 minutes and its density was 0.935 grams / cm³. The residual zirconium content of 1.63 ppmw was calculated based on the mass balance of the reactor.

128 • ·

Example Section IV - Example 2

Ethylene / hexene was prepared in a 35.6 centimeter (14 inch) gas phase polymerization reactor operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lbs / hour), hexene was fed into the reactor at a rate of about 1.6 kilograms / hour (i.e. 3.5 lb / hr) and hydrogen was fed to the reactor at a rate of 11.25 g / hr (i.e. 25 mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e., 5-8 PPH). The polymer production rate was about 9 kilograms / hour (i.e., about 20 PPH). The reactor was equipped with an overpressure device set at 855 kilograms / hour (i.e. 1900 PPH) (said pressurizing device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone. More information on the use of this type of device can be found in U.S. Patent No. 5,693,727). Taper nozzle with an inner diameter of 0.11 centimeters (i.e.

0.041 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1% by weight of catalyst A in toluene was mixed directly with the 1-hexene 0.02 kilogram / hour (i.e. 0.22 lb / hour) and cocatalyst (MMA0-) solution prior to injection into the fluidized bed. 3A in isopentane containing 4 weight percent aluminum). The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 746: 1. If necessary, he was to maintain

129

<img file="CZ20021402A3_D0043.tif" />

• I · 9

9 9

9 Nitrogen and isopentane were fed to the injection nozzle at a constant average particle size of the resulting polymer. This procedure resulted in a single-mode polymer having a nominal melt index of I₂ was 1.2 grams / 10 minutes;₂and

29.7 grams / 10 minutes with an I21 / I2 ratio of 23.9 and a density of 0.9165 grams / cm³. The residual zirconium content of 0.89 ppmw was calculated based on the reactor mass balance.

Example Section IV - Example 3

Ethylene / hexene was prepared in a 35.6 centimeter (14 inch) gas phase polymerization reactor operating at 105 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lbs / hour), hexene was fed into the reactor at a rate of about 0.3 kilograms / hour (i.e. 0.6 lb / hr) and hydrogen was fed to the reactor at a rate of 2.7 g / hr (i.e. 6 mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e., 5-8 PPH). The polymer production rate was approximately

10.8 kilograms / hour (i.e., approximately 24 PPH). The reactor was equipped with an overpressure device set at 720 kilograms / hour (i.e. 1600 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone. Learn more about using this type of device. can be found in U.S. Patent No. 5,693,727). Conical nozzle with an inner diameter of 0.14 centimeters (i.e.

130 ·· ····

0.055 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1.5% by weight of catalyst A in toluene and a cocatalyst (which was a solution of MMAO-3A in 25% of heptane and 75% of hexane containing 1.8% by weight of aluminum) were mixed directly on the production line prior to spraying into the fluidized bed. nozzles. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 320: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂1 was 0.67 grams / 10 minutes and its density was 0.9358 grams / cm³. The residual zirconium content of 2.33 ppmw was calculated based on the mass balance of the reactor.

Example Section IV - Example 4

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 16.3 kilograms / hour (i.e., about 36 lbs / hour), hexene was fed into the reactor at a rate of about 1.6 kilograms / hour (i.e. 3.5 lb / hr) and hydrogen was fed to the reactor at a rate

12.6 grams / hour (i.e. 28 mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 2.0

3.6 kilograms / hour (ie 5-8 PPH). Polymer production rate

131 • · · · ·»·♦

<img file="CZ20021402A3_D0044.tif" />

Was approximately 8.1 kilograms / hour (i.e. approximately 18 PPH). The reactor was equipped with an overpressure device set at 855 kilograms / hour (i.e. 1900 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone.) Learn more about using this type of device. can be found in U.S. Patent No. 5,693,727). A 0.11 centimeter (i.e., 0.041 inch) inner diameter conical nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1% by weight of catalyst A in toluene was mixed directly with the 1-hexene 0.02 kilogram / hour (i.e. 0.22 lb / hour) and cocatalyst (MMA0-) solution prior to injection into the fluidized bed. 3A in isopentane containing 4 weight percent aluminum). The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 925: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂ was 1.7 grams / 10 minutes;₂41.7 grams / 10 minutes, ratio I₂i / I₂ it was 24.1 and its density was 0.917 grams / cm³. The residual zirconium content of 0.94 ppmw was calculated based on the mass balance of the reactor.

Example Section IV - Example 5

In a pilot plant for gas phase polymerization with a diameter of 35.6 centimeters (14 inches) operating at 85 ° C, a pressure of 2.4 megapascal (350 psig) and equipped with

132

9999 • · »·

9 A water-cooled heat exchanger, an ethylene / hexene copolymer was prepared. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lb / hour), hexene was fed into the reactor at a rate of about 0.3 kilograms / hour (i.e., about 0.6 lb / hour) and to the reactor at a rate of 1.58 grams / hour (i.e.

3.5 mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e.

5-8 PPH). The polymer production rate was approximately

9.9 kilograms / hour (i.e. approximately 24 PPH). The reactor was equipped with a pressurizing device set at a power of 675 kilograms / hour (i.e. 1600 PPH) (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone). can be found in U.S. Patent No. 5,693,727). Taper nozzle with an inner diameter of 0.11 centimeters (i.e.

0.041 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1% by weight of catalyst A in toluene and a cocatalyst (which was a solution of MMAO-3A in hexane containing 1% by weight of aluminum) were mixed directly on the production line before being injected into the fluidized bed via said nozzle. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 450: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂1 was 0.10 grams / 10 minutes and its density was 0.931 grams / cm³. Residual zirconium content,

133 ·· · · » · ♦ · • ·

<img file="CZ20021402A3_D0045.tif" />

which was · 1.36 ppmw, was calculated based on the mass balance of the reactor.

Example Section IV - Example 6

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lbs / hour), hexene was fed to the reactor at a rate of about 0.23 kilograms / hour (i.e. 0.5 lb / hr) and hydrogen was fed to the reactor at a rate of 1.8 g / hr (i.e.

mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e. 58 PPH). The polymer production rate was about 9 kilograms / hour (i.e., about 20 PPH). The reactor was equipped with a pressurizing device set at a power of 922.5 kilograms / hour (i.e. 2050 PPH) (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone). More information on the use of this type of device can be found in U.S. Patent No. 5,693,727). A 0.11 centimeter (i.e., 0.041 inch) inner diameter conical nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1 weight percent of catalyst A in toluene and a cocatalyst (which was a solution of MMAO-3A in isopentane containing 4 weight percent aluminum) were mixed directly on the production line before being injected into the fluidized bed via said nozzle. Amount

134 • «1 * I. ,. . ί. · ·: · · ·:: »» »»

The MMAO of the catalyst was controlled so that the Al: Zr molar ratio was 1550: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂1 was 0.36 grams / 10 minutes and its density was 0.943 grams / cm³. The residual zirconium content of 2.5 ppmw was calculated based on the mass balance of the reactor.

Example Section IV - Example 7

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) diameter operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lb / hour), and hexene was fed into the reactor at a rate of about

0.3 kilograms / hour (i.e., about 0.6 lbs / hour) and hydrogen was fed to the reactor at a rate of 5.4 grams / hour (i.e.

mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e. 58 PPH). The polymer production rate was about 9 kilograms / hour (i.e., about 20 PPH). The reactor was equipped with a pressurizing device set at 922.5 kilograms / hour (i.e. 2050 PPH) (said pressurizing device being used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone). More information on the use of this type of device can be found in U.S. Patent No. 5,693,727). Taper nozzle with an inner diameter of 0.11 centimeters (0.041 inches)

<img file="CZ20021402A3_D0046.tif" />

for injecting the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1 weight percent of catalyst A in toluene and a cocatalyst (which was a solution of MMA0-3A in isopentane containing 4 weight percent aluminum) were mixed directly on the production line before being injected into the fluidized bed via said nozzle. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 868: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂I was 3.5 grams / 10 minutes;₂ 0.115 grams / 10 minutes, ratio I₂i / I₂ the density was 0.949 grams / cm³. The residual zirconium content of 2.5 ppmw was calculated based on the mass balance of the reactor.

Example Section IV - Example 8

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) diameter operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 18 kilograms / hour (i.e., about 40 lbs / hour), hexene was fed into the reactor at a rate of about 0.495 kilograms / hour (i.e. 1.1 lb / h) and hydrogen was fed to the reactor at a rate of 5.4 g / h (12 mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e.

5-8 PPH). The polymer production rate was approximately

11.25 kilograms / hour (i.e., approximately 25 PPH). Said reactor

136 Byl it · it was equipped with an overpressure device set to a power of 855 kilograms / hour (ie 1900 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone). This type of device can be found in U.S. Patent No. 5,693,727). Taper nozzle with an inner diameter of 0.11 centimeters (i.e.

0.041 inch) for injection! The catalyst was placed in a gas stream in said plenum. A solution containing 1 weight percent of catalyst A in toluene and a cocatalyst (which was a solution of MMAO-3A in isopentane containing 4 weight percent aluminum) were mixed directly on the production line before being injected into the fluidized bed via said nozzle. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 842: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure yielded a single-mode polymer having a nominal melt index of 1₂i was 41.2 grams / minute;₂ 1.22 grams / 10 minutes, the I21 / I2 ratio was 33.8 and its density was 0.940 grams / cm³. The residual zirconium content of 2.77 ppmw was calculated based on the mass balance of the reactor.

Example Section IV - Example 9

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) diameter operating at 90 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate

137 * About 21.6 kilograms / hour (i.e. about 48 lbs / hour), hexene was injected into the reactor at a rate of about 0.3 kilograms / hour (i.e. about 0.6 lbs / hour) and further hydrogen was fed to the reactor at a rate of 4.5 grams / hour (i.e.

mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e., 5-8 PPH). The polymer production rate was approximately

10.35 kilograms / hour (i.e., approximately 23 PPH). The reactor was equipped with an overpressure device set at 720 kilograms / hour (i.e. 1600 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone. Learn more about using this type of device. can be found in U.S. Patent No. 5,693,727). Conical nozzle with an inner diameter of 0.14 centimeters (i.e.

0.055 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1.5% by weight of catalyst A in toluene and a cocatalyst (which was a solution of MMAO-3A in a mixture of 25% heptane and 75% hexane containing 1.8% by weight aluminum) were mixed directly on the production line before spraying into the fluidized bed. said nozzles. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 265: 1. Nitrogen and isopentane were fed to the injection nozzle as needed to maintain a constant average particle size of the polymer formed. This procedure resulted in a single-mode polymer having a nominal melt index of I₂1 was 0.3 grams / 10 minutes and its density was 0.933 grams / cm³. The residual zirconium content of 2.38 ppmw was calculated based on the mass balance of the reactor.

138

0 * ·

<img file="CZ20021402A3_D0047.tif" />

<img file="CZ20021402A3_D0048.tif" />

Example Section IV - Example 10

Ethylene / hexene was prepared in a pilot gas-phase polymerization reactor of 35.6 centimeters (14 inches) operating at 95 ° C, 2.4 megapascal (350 psig) and equipped with a water-cooled heat exchanger. copolymer. Ethylene was fed to the reactor at a rate of about 20.25 kilograms / hour (i.e., about 45 lb / hour), hexene was fed into the reactor at a rate of about 0.3 kilograms / hour (i.e. 0.6 lb / hr) and hydrogen was fed to the reactor at a rate of 4.5 g / hr (i.e.

mPPH). Further, nitrogen was fed to the reactor at a rate of 2.25 to 3.6 kilograms / hour (i.e., 5-8 PPH). The polymer production rate was approximately

11.25 kilograms / hour (i.e., approximately 25 PPH). The reactor was equipped with an overpressure device set at 720 kilograms / hour (i.e. 1600 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-poor zone. Learn more about using this type of device. can be found in U.S. Patent No. 5,693,727). Conical nozzle with an inner diameter of 0.14 centimeters (i.e.

0.055 inch) to inject the catalyst was placed in a gas stream in said pressurizing device. A solution containing 1.5 weight percent Catalyst A in toluene and a cocatalyst (which was a solution of MMAO-3A in a mixture of 25 percent heptane and 75 percent hexane containing 1.8 weight percent aluminum) were mixed directly on the production line before spraying into the fluidized bed using said nozzles. The amount of MMAO catalyst was controlled so that the Al: Zr molar ratio was 350: 1. If necessary, he was to maintain

139

<img file="CZ20021402A3_D0049.tif" />

a constant average particle size of the resulting polymer was fed to the nozzle with nitrogen and isopentane. This procedure resulted in a single-mode polymer having a nominal melt index of I_2i was 0.4 grams / 10 minutes and its density was 0.934 grams / cm³. The residual zirconium content of 2.27 ppmw was calculated based on the reactor mass balance.

For the sake of clarity, the data presented in Examples 1 to 10 of Example IV are summarized again in Table II

Table II

<td>Example</td><td>Temperature Deň: 32 ° C</td><td>h₂/C₂</td><td>C₆/C₂</td><td>AND₂g / 10 min</td><td>Izi g / 10 min</td><td>Density g / cm³</td><td>Residual obsah Zr ppmw</td>

<td> 1</td><td> 85</td><td> 0,0015</td><td> 0,0043</td><td>on</td><td> 0,28</td><td> 0,935</td><td> 1, 63</td>

<td> 2</td><td> 85</td><td> 0,008</td><td> 0,0410</td><td> 1,2</td><td> 29, 7</td><td> 0,9165</td><td> 0,89</td>

<td> 3</td><td> 105</td><td> 0,0015</td><td> 0,0050</td><td>on</td><td> 0,67</td><td> 0,9358</td><td> 2,33</td>

<td> 4</td><td> 85</td><td> 0,0087</td><td> 0,0450</td><td>Γ ,-AND</td><td> 41,7</td><td> 0, 917</td><td> 0,94</td>

<td> 5</td><td> 85</td><td> 0,0006</td><td> 0,0051</td><td>on</td><td> 0,1</td><td> 0,931</td><td> 1,36</td>

<td> 6</td><td> 85</td><td> 0,0023</td><td> 0,0012</td><td>on</td><td> 0,36</td><td> 0,943</td><td> 2,50</td>

<td> 7</td><td> 85</td><td> 0,0051</td><td> 0,0013</td><td> 0,115</td><td> 3,5</td><td> 0,949</td><td> 2,50</td>

<td> 8</td><td> 85</td><td> 0,0114</td><td> 0,0154</td><td> 1,22</td><td> 41,2</td><td> 0,940</td><td> 2,77</td>

<td> 9</td><td> 90</td><td> 0,0015</td><td> 0,0050</td><td>on</td><td> 0,3</td><td> 0,933</td><td> 2,38</td>

<td> 10</td><td> 95</td><td> 0,0015</td><td> 0,0050</td><td>on</td><td> 0,4</td><td> 0, 934</td><td> 2,27</td>

140 • 0 · 0 · · · 0-0-0 0 0 * ·

<img file="CZ20021402A3_D0050.tif" />

Example Section IV-Example 11

138 kilograms (300 pounds) of the polyethylene produced in Example 4 (referred to as polymer A) was mixed with 1000 ppm Irganox® 1076 and 1500 ppm Irgafos® 1068 at a melt temperature of 200 ° C in a two-screw extruder Werner-Fleiderer ZSK-30. was formed into pellets. A 25 micron (1.0 mil) sheet was blown from the pellets on a Gloucester extrusion line. The film was made under the following extrusion conditions: line performance 85 kilograms / hour (188 lb / hour), melt temperature 199 ° C (390 ° F), solidification line height 61 centimeters (24 inches), blow rate 2.5 at slot width 1524 micrometers (60 miles). For comparison, Escorene® HD7755.10 (which is a commercially available product from Exxon Chemical Company Houston, Texas, USA, manufactured in a series of reactors) was processed under the same conditions.

All films were aged for 40 hours at 23 ° C and 50% humidity. The properties of the individual films are summarized in Tables III and IV.

Table III

<td>Example</td><td>Escorene® LL3002.32</td><td>Polymer A flow index melt 1.8 g / 10 min</td><td>Escorene® LL3001.63</td>

<td>AND₂ (g / 10 min)</td><td> 2</td><td> 1076</td><td> 1</td>

<td>I21 / I2</td><td> 29</td><td> 24</td><td> 27</td>

<td>Pellet density (g / cm^J)</td><td> 0,918</td><td> 0,918</td><td> 0,918</td>

141

Table III - completion

<td>Example</td><td>Escorene® LL3002.32</td><td>Polymer A flow index melt 1.8 g / 10 min</td><td>Escorene® LL3001.63</td>

<td>Pressure on the extrusion head (MPa (psi))</td><td> 19 (2690)</td><td> 17 (2470)</td><td> 23 (3380)</td>

<td>Motor load (%)</td><td> 43</td><td> 31,2</td><td> 50,4</td>

<td>Foil thickness (pm (mil))</td><td> 25 (1)</td><td> 25 (1)</td><td> 25 (1)</td>

<td>Foil density (g / cm³)</td><td> 0,917</td><td> 0,916</td><td> 0,917</td>

<td>66cm (26) arrow (gram)¹</td><td> 136</td><td> 168</td><td> 149</td>

<td>MD retention (g / pm (g / m))</td><td> 12,7 (310)</td><td> 10,4 (254)</td><td> 9,1 (223)</td>

<td>TD retention (g / pm (g / m))</td><td> 24,9 (609)</td><td> 25,7 (630)</td><td> 30,7 (753)</td>

<td>1% MD (MPa (psi))</td><td> 210 (30430)</td><td> 218 (31580)</td><td> 216 (31320)</td>

<td>1% TD (MPa (psi))</td><td> 269 (38950)</td><td> 290 (42120)</td><td> 274 (39750)</td>

<td>MD limit strength (MPa (dogs))</td><td> 51 (7444)</td><td> 59 (8551)</td><td> 61 (8880)</td>

<td>TD ultimate strength (MPa (dogs))</td><td> 45 (6498)</td><td> 68 (9892)</td><td> 48 (6894)</td>

<td>Ultimate elongation MD (%)</td><td> 641</td><td> 546</td><td> 552</td>

<td>Ultimate elongation TD (%)</td><td> 793</td><td> 694</td><td> 756</td>

<td>45 ° gloss</td><td> 40</td><td> 79</td><td> 23</td>

<td>Turbidity (%)</td><td> 22</td><td> 4,4</td><td> 20</td>

The meaning of the individual abbreviations is the same as in the previous tables.

142 * «

9·*· * ***

Table IV

<td>Example</td><td>Polymer A flow index melt 1.3 g / 10 min</td><td>Exceed® 350D60</td>

<td>AND₂ (g / 10 min)</td><td> 1,35</td><td> 1</td>

<td>WI₂</td><td> 23</td><td> 16</td>

<td>Pellet density (g / crr?)</td><td> 0, 918</td><td> 0,918</td>

<td>Pressure on extrusion head (MPa (psi))</td><td> 21 (3010)</td><td> 26 (3810)</td>

<td>Motor load (%)</td><td> 37,2</td><td> 56, 7</td>

<td>Foil thickness (pm (mil))</td><td> 25 (1)</td><td> 25 (1)</td>

<td>Foil density (g / cm³)</td><td> 0,916</td><td> 0,916</td>

<td>66cm (26) arrow (gram)¹</td><td> 276</td><td> 646</td>

<td>MD hold (g / pm (g / mil))</td><td> 8,9 (219)</td><td> 10,8 (264)</td>

<td>TD tear (g / pm (g / mil))</td><td> 25,1 (616)</td><td> 16 (392)</td>

<td>1% MD (MPa (psi))</td><td> 214 (31100)</td><td> 200 (29040)</td>

<td>1% TD (MPa (psi))</td><td> 286 (41470)</td><td> 228 (33050)</td>

<td>MD ultimate strength (MPa (psi))</td><td> 62 (9017)</td><td> 69 (9986)</td>

<td>TD ultimate strength (MPa (psi))</td><td> 53 (7684)</td><td> 59 (8535)</td>

<td>Ultimate elongation MD (%)</td><td> 529</td><td> 504</td>

<td>Ultimate elongation TD (%)</td><td> 690</td><td> 646</td>

<td>45 ° gloss</td><td> 74</td><td> 25</td>

<td>Turbidity (%)</td><td> 5</td><td> 23</td>

The meaning of the individual abbreviations is the same as in the previous tables.

The examples in Example V describe the use of a feed solution of a mixed catalyst system which

143

<img file="CZ20021402A3_D0051.tif" />

it comprises a catalytic metal compound comprising a Group 15 element and a sterically bulky ligand metallocene catalyst.

EXAMPLE V Injection of a mixed catalyst system solution comprising a catalytic metal compound comprising a Group 15 element and a sterically bulky ligand metallocene catalyst.

Catalyst 1

For the purposes of Example V, Catalyst 1 was indenyl zirconium trispivalate, a sterically bulky ligand metallocene compound prepared as described in Example I.

Preparation of Catalyst 1 as a 1% by weight solution in hexane

All operations described below took place in a dry cabinet.

To a 1 liter Erlenmeyer flask equipped with a Teflon coated stirrer was charged 1 liter of purified hexane. To the hexane was added 6.67 grams of indenyl zirconium trispivalate as a dry powder. The resulting solution was allowed to stir for 15 minutes, during which time all solids dissolved. The resulting catalyst solution was transferred to a clean 1 liter Whitey cylinder, which was subsequently labeled, removed from the dry box, and placed in a holder where it was ready for later use.

144

4 4 4 • 4

4*4 ·· ♦

4 1 • 44 • · 4 •» ····

Catalyst 2

For the purposes of Example V, Catalyst 2, [(2,4,6Me₃C₆H₂) NHCH₂CH₂] ₂NH ligand (or ligand 1) and {[(2,4,6Me₃C6H₂) NCH₂CH₂] ₂NH} Zr (CH₂Ph) ₂ or (compound I) prepared according to the procedures described in Example I above.

Preparation of Catalyst 2 as a 1.5 wt% solution in toluene

All operations described below took place in a dry cabinet.

100 grams of purified toluene were weighed into a 1 liter Erlenmeyer flask equipped with a Teflon coated stirrer. 7.28 grams of tetrabenzyl zirconium was added to the toluene and the resulting solution was allowed to stir for 5 minutes, during which time all the solid dissolved. To the solution was added 5.42 grams of ligand I as described above and another 551 grams of purified toluene. The mixture was allowed to stir for 15 minutes, again dissolving all solids. The resulting catalyst solution was transferred to a clean 1 liter Whitey cylinder, which was subsequently labeled, removed from the dry box, and placed in a holder where it was ready for later use.

Example section V-example 1

In a pilot plant for gas phase polymerization with a diameter of 35.6 centimeters (14 inches) operating at 85 ° C, 2.4 megapascal (350 psig) and equipped with

145 • · · »ί ί ί ί ί ί ί ί« «« «« «« «« ί An ethylene / hexene copolymer was prepared with a water-cooled heat exchanger. The reactor was equipped with an overpressure device set at 720 kilograms / hour (i.e. 1600 PPH) (said overpressure device is used in a fluidized bed gas phase polymerization reactor to form a polymer particle-free zone). More information on the use of this type of device can be found in U.S. Patent No. 5,693,727). A 0.14 centimeter (i.e., 0.055 inch) inner diameter nozzle for injecting the catalyst was placed in a gas stream in said pressurizing device. Prior to catalyst injection, the ethylene pressure was approximately 1.5 megapascal (i.e. about 220 psia), the 1-hexene concentration was about 0.3 mole percent and the hydrogen concentration was about 0.12 mole percent.

Catalyst 2 solution was diluted with toluene to 0.5 weight percent and this solution was injected into the reactor at a rate of 12 cm³/ hour. The cocatalyst (which was MMAO-3A containing 1 weight percent aluminum) was mixed with catalyst 2 directly in the pipeline before being injected into the reactor, the Al / Zr molar ratio being 400: 1. The polymer production rate was about 10.9 kilograms / hour (i.e., about 24 PPH). Further, it was fed to the injection nozzle

2.3 kilograms / hour (5.0 lbs / hour) of nitrogen, 0.05 kilograms / hour (0.1 lbs / hour) of 1-hexene and 0.09 kilograms / hour (0.2 lbs / hour) of isopentane. The resulting polymer had a melt index of 0.31 and a density of 0.935 grams / cm³. After formation of this polymer, the flow of catalyst 2 was reduced to 6 cm³/ hour and was fed to the feed line at a rate of 13 cm³solution / catalyst 1 in hexane

146

<td> • &lt;444</td><td>• W</td><td>MM</td><td colspan="3"> • 4</td><td colspan="2"> • 4</td>

<td> • 4 4</td><td> 4</td><td> 4 4</td><td> •</td><td></td><td> •</td><td> 4</td><td> «</td>

<td> 4 4</td><td> 4</td><td> • 4</td><td> 4</td><td></td><td> 4</td><td></td><td> 4</td>

<td> 4 4</td><td> 4</td><td> 4 4</td><td> 4</td><td></td><td> 4</td><td> 4</td><td></td>

<td> 4 4 4 4</td><td> 4 *</td><td> •</td><td></td><td> 4 *</td><td></td><td> 4 44</td><td> 4</td>

a concentration of 0.125 weight percent. The whole order of mixing proceeded by first mixing hexene and MMAO with catalyst 1, adding catalyst solution 2, and then adding isopentane and nitrogen to the resulting mixture.

The Al / Zr ratio in the whole system described above was approximately 500. Within 6 hours of the start of the addition of Catalyst 1, a bimodal polymer was formed whose nominal melt index I_2i was 12.9 grams / 10 minutes, melt index ratio (MFR) I₂i / I₂ was 130 and its density was 0.953 grams / cm³. The average particle size of the resulting polymer was 0.12 centimeters (i.e., 0.0479 inches). The residual zirconium content of 0.7 ppmw was determined by X-ray fluorescence spectroscopy.

The contents of all documents cited above, priority documents and / or documents describing the test methods are incorporated herein by reference. As will be apparent from the foregoing general description and from the description of specific embodiments of the present invention, numerous changes may be made to the specific procedures described above without departing from the scope of the invention. The invention also encompasses the use of two or more metal compounds comprising an element of 15. groups of the Periodic Table of the Elements together with one or more metallocene-based catalyst compounds with a sterically bulky ligand and / or one or more conventional catalyst systems. Accordingly, it is not intended to limit the scope of the present invention in any way.