Abstract: Techniques are provided for catalyst preparation. A system for catalyst preparation may include an agitator disposed inside a polymerization catalyst tank and configured to mix a polymerization catalyst and a solvent to generate a polymerization catalyst solution. The system may also include a heating system coupled to the polymerization catalyst tank and configured to maintain a temperature of the polymerization catalyst solution above a threshold. The system may also include a precontactor configured to receive feed streams comprising an activator and the polymerization catalyst solution from the polymerization catalyst tank to generate a catalyst complex. The system may also include a transfer line configured to transfer the catalyst complex from an outlet of the precontactor to a reactor.

Abstract: A method comprising (a) contacting a support and a chromium-containing compound to form chromium-containing support, (b) heat treating the chromium-containing support in an oxidizing atmosphere to form a treated support, (c) contacting the treated support with carbon monoxide to form a CO-contacted support, and (d) contacting the CO-contacted support with hydrogen to form a catalyst. A method comprising oxidizing a chromium-treated support to form a polymerization catalyst, contacting the polymerization catalyst with carbon monoxide to form a reduced polymerization catalyst, contacting the reduced polymerization catalyst with hydrogen to form an activated polymerization catalyst, and contacting the activated polymerization catalyst with ethylene in a reaction zone under suitable reaction conditions to form a random copolymer.

Abstract: This invention relates to the field of olefin polymerization catalyst compositions, and methods for the polymerization and copolymerization of olefins, including polymerization methods using a supported catalyst composition. In one aspect, the present invention encompasses a catalyst composition comprising the contact product of a first metallocene compound, a second metallocene compound, at least one chemically-treated solid oxide, and at least one organoaluminum compound. The new resins were characterized by useful properties in impact, tear, adhesion, sealing, extruder motor loads and pressures at comparable melt index values, and neck-in and draw-down.

Abstract: Systems and methods for the maintenance of active chromium-based catalysts and their use in polymerization processes are described. In one embodiment, a system for the introduction of multiple polymerization components to activate a chromium based catalyst within a mix tank is described. Other described features may include materials and methods to purify the liquid medium of a catalyst slurry so that the catalyst slurry maintains a high level of activity. The active chromium-based catalyst may provide polyolefins with a number of desirable properties in a reliable, consistent, and predictable manner.

Abstract: A system and method for activating chromium catalyst, including: increasing temperature of a chromium catalyst at a first rate for a first period of time to a first temperature; and increasing temperature of the chromium catalyst at a second rate for a second period of time from the first temperature to a second temperature, wherein the first rate is greater than the second rate, and wherein the first period precedes the second period.

Abstract: Methods and systems for preparing catalyst, such as chromium catalysts, are provided. The valence of at least a portion of the catalyst sent to an activator is changed from Cr(III) to Cr(VI). The catalyst is prepared or activated continuously using a fluidization bed catalyst activator.

Abstract: A method comprising contacting an olefin in the presence of a catalyst and a melt index modifier (MIM) under conditions suitable to form a polyolefin and recovering the polyolefin, wherein the polyolefin melt index is increased by at least about 25%, wherein the normalized catalyst activity is decreased by less than about 10%, and wherein the MIM is characterized by the general formula R1—HC?CH—R2 or R3R4C?CH2 where R1, R2, R3, R4 are each selected from the group consisting of a non-aromatic organyl group.

Abstract: The present invention provides polymerization catalyst compositions employing half-metallocene compounds with a heteroatom-containing ligand bound to the transition metal. Methods for making these hybrid metallocene compounds and for using such compounds in catalyst compositions for the polymerization and copolymerization of olefins are also provided.

Abstract: A method of preparing a catalyst comprising aging a silica support in an alkaline solution to produce an alkaline aged silica support, removing at least a portion of the alkaline solution from the alkaline aged silica support to produce a dried silica support, and activating the silica support to produce a catalyst composition, wherein alkaline aging lowers the surface area of the silica support to less than about 50% of the original value and wherein activation of the silica support is carried out in batches of equal to or greater than about 500 lbs for a time period of less than about 8 hours.

Abstract: The present invention provides polymerization catalyst compositions employing half-metallocene compounds with a heteroatom-containing ligand bound to the transition metal. Methods for making these hybrid metallocene compounds and for using such compounds in catalyst compositions for the polymerization and copolymerization of olefins are also provided.

Abstract: Methods and systems for preparing catalyst, such as chromium catalysts, are provided. The valence of at least a portion of the catalyst sent to an activator is changed from Cr(III) to Cr(VI). The catalyst is prepared or activated continuously using a fluidization bed catalyst activator.

Abstract: In an embodiment, a method is disclosed to increase the activity of an ionic liquid catalyst comprising emulsifying the ionic liquid catalyst with one or more liquid components. In an embodiment, a method is disclosed comprising introducing into a reaction zone a monomer feed and a reduced amount of ionic liquid catalyst and controlling an amount of shear present in the reaction zone to maintain a desired conversion reaction of the monomer. In an embodiment, a catalyzed reaction system is disclosed comprising a reactor configured to receive one or more liquid components and ionic liquid catalyst; a device coupled to the reactor for adding high shear to the liquid components and ionic liquid catalyst; and a controller coupled to the device for adding high shear and configured to control the amount of shear added to a catalyzed reaction zone to maintain a conversion reaction.

Abstract: Systems and methods for the maintenance of active chromium-based catalysts and their use in polymerization processes are described. In one embodiment, a system for the introduction of multiple polymerization components to activate a chromium based catalyst within a mix tank is described. Other described features may include materials and methods to purify the liquid medium of a catalyst slurry so that the catalyst slurry maintains a high level of activity. The active chromium-based catalyst may provide polyolefins with a number of desirable properties in a reliable, consistent, and predictable manner.

Abstract: Methods and systems for preparing catalyst, such as chromium catalysts, are provided. The valence of at least a portion of the catalyst sent to an activator is changed from Cr(III) to Cr(VI). The catalyst is prepared or activated continuously using a fluidization bed catalyst activator.

Abstract: The present invention provides polymerization catalyst compositions employing half-metallocene compounds with a heteroatom-containing ligand bound to the transition metal. Methods for making these hybrid metallocene compounds and for using such compounds in catalyst compositions for the polymerization and copolymerization of olefins are also provided.

Abstract: This invention relates to the field of olefin polymerization catalyst compositions, and methods for the polymerization and copolymerization of olefins, including polymerization methods using a supported catalyst composition. In one aspect, the present invention encompasses a catalyst composition comprising the contact product of a first metallocene compound, a second metallocene compound, at least one chemically-treated solid oxide, and at least one organoaluminum compound. The new resins were characterized by useful properties in impact, tear, adhesion, sealing, extruder motor loads and pressures at comparable melt index values, and neck-in and draw-down.

Abstract: This invention relates to the field of olefin polymerization catalyst compositions, and methods for the polymerization and copolymerization of olefins, including polymerization methods using a supported catalyst composition. In one aspect, the present invention encompasses a catalyst composition comprising the contact product of a first metallocene compound, a second metallocene compound, at least one chemically-treated solid oxide, and at least one organoaluminum compound. The new resins were characterized by useful properties in impact, tear, adhesion, sealing, extruder motor loads and pressures at comparable melt index values, and neck-in and draw-down.

Abstract: A system and method for activating chromium catalyst, including: increasing temperature of a chromium catalyst at a first rate for a first period of time to a first temperature; and increasing temperature of the chromium catalyst at a second rate for a second period of time from the first temperature to a second temperature, wherein the first rate is greater than the second rate, and wherein the first period precedes the second period.

Abstract: In an embodiment, a method is disclosed to increase the activity of an ionic liquid catalyst comprising emulsifying the ionic liquid catalyst with one or more liquid components. In an embodiment, a method is disclosed comprising introducing into a reaction zone a monomer feed and a reduced amount of ionic liquid catalyst and controlling an amount of shear present in the reaction zone to maintain a desired conversion reaction of the monomer. In an embodiment, a catalyzed reaction system is disclosed comprising a reactor configured to receive one or more liquid components and ionic liquid catalyst; a device coupled to the reactor for adding high shear to the liquid components and ionic liquid catalyst; and a controller coupled to the device for adding high shear and configured to control the amount of shear added to a catalyzed reaction zone to maintain a conversion reaction.

Abstract: New methods for activating chromium catalysts for polymerization processes decrease the amount of time required for activation and increase catalyst activity. Rapid heating to a first temperature is followed by a first hold period before heating to a higher second temperature and maintaining the second temperature for a second hold period. In one aspect, the overall activation process takes less than 10 hours.