Abstract: Supported stereospecific catalysts and processes for the stereotactic propagation of a polymer chain derived from ethylenically unsaturated monomers which contain three or more carbon atoms or which are substituted vinyl compounds, specifically alpha olefins, particularly the polymerization of propylene to produce syndiotactic or isotactic polypropylene. The supported metallocene catalyst comprises a stereospecific metallocene catalyst and a co-catalyst component comprising at least one of an alkyl alumoxane and an alkylaluminum compound. Both the metallocene catalyst and the co-catalyst are supported on a particulate silica support comprising silica particles having an average particle size of 5–40 microns and an average effective pore size of 50–200 angstroms. The silica support further has a differential pore size distribution of a pore volume of at least 0.01 cm3/g. within a range having a maximum pore width of no more than 300 angstroms.

Abstract: A process for the preparation of a pyridinyl-linked bis-amino ligand that comprises, (a) reacting 2,6-dibromophenyl amine with an arylboronic acid component which is substituted or unsubstituted to produce a 2,6-diarylphenyl amine which is substituted or unsubstituted; (b) reacting the 2,6-diarylphenyl amine with a 2,6-dialkanoic pyridine characterized by the formula: wherein R? and R? are each independently a C1–C20 hydrocarbyl group; to produce a mono-imine ligand characterized by the formula: wherein TRP is a terphenyl group which is substituted or unsubstituted; and (c) reacting the mono-imine ligand with an aniline which may be substituted or unsubstituted to produce a bis-amine ligand characterized by the structure: wherein: TRP is a substituted or unsubstituted terphenyl group; and AR is a substituted or unsubstituted aryl group.

Abstract: A pre-catalyst is formed by reacting butylethylmagnesium with an alcohol to form a magnesium alkoxide compound, followed by contacting the magnesium alkoxide compound with a phosphorous compound to form a magnesium alkoxide phosphorous compound mixture. The magnesium alkoxide phosphorous compound mixture is subsequently reacted with TiCl4 to form a MgCl2 support. The MgCl2 support is then contacted with an internal donor while being heated to form a first catalyst slurry, which is then contacted with TiCl4 while being heated to form a second catalyst slurry. The second catalyst slurry is next contacted with TiCl4 while being heated to form a third catalyst slurry, which is washed and dried, resulting in a highly active pre-catalyst with controlled morphology. The pre-catalyst may be combined with one or more co-catalysts and optionally one or more external electron donors to form an active catalyst system, which may be used for the polymerization of olefins.

Abstract: It has been discovered that using di-sec-butyldialkoxysilanes, such as di-sec-butyldimethoxysilane (DSBDMS), as external electron donors for Ziegler-Natta catalysts can provide a catalyst system that may prepare polypropylene films with improved properties and processing. The catalyst systems of the invention provide high activity, high bulk density, moderate hydrogen response, moderate donor response and high polydispersity (MWD). Suitable di-sec-butyldialkoxysilanes have the formula (sBu)2Si(OR?)2, where R? is independently a straight or branched alkyl group of 1–5 carbon atoms.

Abstract: Articles of manufacture and a method of making the articles are provided. The articles of manufacture comprise CpFlu metallocene catalyzed polypropylene homopolymers and C2–C3 random copolymers having narrow molecular weight distributions and low xylene solubles (or extractables) contents. Because of a number of desirable properties, the polypropylene homopolymers and C2–C3 random copolymers may be used to prepare a wide variety of useful articles, including but not limited to cast films, such as packaging; fibers suitable for use in fabrics and carpet applications, and injection and blow molded items such as bottles.

Abstract: It has been discovered that using n-butylmethyldimethoxysilane (BMDS) as an external electron donor for Ziegler-Natta catalysts can provide a catalyst system that may prepare polypropylene films with improved properties. The catalyst systems of the invention provide for controlled chain defects/defect distribution and thus a regulated microtacticity. Consequently, the curve of storage modulus (G?) v. temperature is shifted such that the film achieves the same storage modulus at a lower temperature enabling faster throughput of polypropylene film through a high-speed tenter.

Abstract: A process for the reduction of a phenylacetylene contaminant in the presence of a styrene monomer. A styrene monomer stream containing a minor amount of phenylacetylene is supplied to a hydrogenation reactor. A hydrogenation gas comprising hydrogen is also supplied to the hydrogenation reactor. The styrene monomer stream and the hydrogen are brought into contact with a catalyst bed containing a catalyst comprising a reduced copper compound on a theta alumina support. The hydrogenation reactor is operated at a temperature of at least 60° C. and a pressure of at least 30 psig to hydrogenate phenylacetylene to styrene. A product is recovered from the hydrogenation reactor having a substantially reduced phenylacetylene content and an enhanced styrene content. The hydrogenation gas comprises a mixture of nitrogen and hydrogen.

Abstract: The present invention provides an apparatus and method of reducing volatiles in a mass processable polymer. The apparatus includes a multi-chambered devolatilizer having first and second collectors contained therein. In one embodiment, the invention provides a method that includes passing the mass processable polymer stream from a polymerization process to a first devolatilizer. The method continues by passing the polymer stream from the first devolatilizer to the multi-chambered devolatilizer. The apparatus and method allows for the production of a polymer having less than 100 ppm of volatiles.

Abstract: It has been discovered that using di-sec-butyldialkoxysilanes, such as di-sec-butyldimethoxysilane (DSBDMS), as external electron donors for Ziegler-Natta catalysts can provide a catalyst system that may prepare polypropylene films with improved properties and processing. The catalyst systems of the invention provide high activity, high bulk density, moderate hydrogen response, moderate donor response and high polydispersity (MWD). Suitable di-sec-butyldialkoxysilanes have the formula (SBu)2Si(OR?)2, where R? is independently a straight or branched alkyl group of 1–5 carbon atoms.

Abstract: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.

Abstract: The present invention relates to propylene polymerization process in a bulk loop reactor, and particularly to propylene polymerization process for polymerizing commercial quantities of polypropylene in a bulk loop reactor by sequentially introducing Ziegler-Natta and metallocene catalyst systems into the bulk loop reactor.

Abstract: The tendency of copolymer fluff grains of propylene and ethylene to agglomerate is reduced by injecting at least one olefin comonomer, such as ethylene monomer, into more than one point along the length of the reactor, rather than injecting all of the ethylene at one point. This process reduces the tendency of copolymer fluff grains to agglomerate and cause processing problems as compared with injecting the comonomer at only one point. Copolymer made by this process is expected to have lower substantially amorphous polypropylene content and better organoleptics than copolymer made where the ethylene is injected at only one point. In one non-limiting embodiment the copolymerization reactor is a loop-type reactor.

Abstract: Disclosed is a method of modifying polyethylene to increase its ability to resist the transmission of water vapor. The polyethylene is modified to increase long chain branching resulting in lower water vapor transmission rates in films prepared with the modified polyethylene. The polyethylene can be modified using peroxides, air and even by admixture with high long chain branching content polyethylene. The polyethylene, particularly when in the form of films, can be used for preparing packaging where sorption of flavor, aroma, or colorant compounds must be minimized.

Abstract: A method and apparatus are disclosed for purifying copolymer compounds having monovinyl aromatic blocks and conjugated diene blocks by reducing the residual monomer content of the finished polymer. The method and apparatus includes a combination of heat exchangers and devolatilizers used in conjunction with a copolymerization reactor system.

Abstract: A Ziegler-Natta type catalyst component can be produced by a process comprising contacting a magnesium dialkoxide compound with a halogenating agent to form a reaction product A, and contacting reaction product A with a first, second and third halogenating/titanating agents. Catalyst components, catalysts, catalyst systems, polyolefin, products made therewith, and methods of forming each are disclosed. The reaction products can be washed with a hydrocarbon solvent to reduce titanium species [Ti] content to less than about 100 mmol/L.

Abstract: An improved method of manufacturing blown polyolefin films with increased bubble stability and higher blown film production rates is disclosed. A method in which the amounts and ratios of known antioxidant polymer film additives (phosphites and phenolics) are controlled to provide limited long chain branching (LCB) and greater rheological breadth in a polyethylene melt to improve both processing characteristics and mechanical properties in the resulting film.

Abstract: The present invention relates to propylene polymerization process in a bulk loop reactor, and particularly to propylene polymerization process for polymerizing commercial quantities of polypropylene in a bulk loop reactor by sequentially introducing Ziegler-Natta and metallocene catalyst systems into the bulk loop reactor. In one embodiment, separate catalyst mixing systems are used to introduce a quantity of metallocene catalyst and Ziegler-Natta catalyst into the bulk loop reactor. The frequency rate at which the quantity of metallocene catalyst is introduced into the bulk loop reactor may be higher than the frequency rate at which the quantity of Ziegler-Natta catalyst is introduced.

Abstract: A catalyst system having the following formula is described herein. wherein M is a metal; each X is an atom or group banded to M and may be the same or different; R1 and R2 may be the same or each may be different and are substituted or unsubstituted cyclopentadienyl or aromatic groups; RB is a structural bridge between R1 and R2 imparting stereorigidity thereto and including at least one heteroatom bonded to M, with each of R1 and R2 bonded to the same or different heteroatom of RB which heteroatom is also bonded to M; Z is the coordination number of M and is greater than or equal to 4 and m is the number of bonds between M and heteroatoms of RB.

Abstract: Supported metallocene catalysts and processes for the use of such catalysts in isotactic polymerization of a C3+ ethylenically unsaturated monomer. The supported catalysts comprise a particulate silica support, an alkyl alumoxane component, and a metallocene catalyst component. The support has an average particle size of 10-50 microns, a surface area of 200-800 m2/g and a pore volume of 0.9-2.1 milliliters per gram (ml/g). Alumoxane is incorporated onto the support to provide a weight ratio of alumoxane to silica of at least 0.8:1.