Abstract: Catalyst systems and methods for making and using the same are provided. The catalyst systems can include a plurality of silica particles and a metallocene catalyst and an activator supported on the plurality of silica particles. The polymerization catalysts have a particle size distribution in which about 10% of the particles have a size less than about 17 to about 23 micrometers, about 50% of the particles have a size less than about 40 to about 45 micrometers, and about 90% of the particles have a size less than about 72 to about 77 micrometers.

Abstract: Methods for producing catalyst systems with increased productivity are disclosed. The methods may comprise providing a catalyst composition comprising a solvent and a single-site catalyst component, heating an inert gas to a temperature in a range of from about 100° C. to about 150° C., and spray drying the catalyst composition in the presence of the inert gas to form a spray-dried catalyst system. Additionally, the methods may comprise providing a catalyst composition comprising a solvent, an activator, a filler material, a metallocene catalyst, and a Group 15-containing catalyst; heating an inert gas to a temperature in a range of from about 100° C. to about 150° C.; and spray drying the catalyst composition in the presence of the inert gas to form a spray-dried catalyst system.

Abstract: Catalyst systems and methods for making and using the same are provided. The catalyst system can include a catalyst support, wherein the catalyst support has an average particle size of about 2 microns to about 200 microns. Nanoparticles are adhered to the catalyst support, wherein the nanoparticles have an average particle size of about 2 to about 200 nanometers. A catalyst is supported on the catalyst support.

Abstract: Embodiments of our invention relate to processes for transitioning among polymerization catalyst systems including processes for transitioning among olefin polymerization reactions using Ziegler-Natta catalysts systems and chromium-based catalyst systems. Among embodiments contemplated are a method of transitioning from a first catalyst to a second catalyst in an olefin polymerization reactor, comprising: adding to the reactor a deactivating agent (DA) selected from one of carbon monoxide, carbon dioxide, or combinations thereof; adding to the reactor a cocatalyst adsorbing agent (CAA), comprising an inorganic oxide selected from one of silica, alumina or combinations thereof; wherein the first catalyst comprises at least one conventional Ziegler-Natta catalyst, and a cocatalyst, wherein the second catalyst comprises at least one chromium-based catalyst, wherein the reactor is a gas-phase, fluidized bed reactor, and wherein the CAA is substantially free of transition metals.

Abstract: Processes for transitioning among polymerization catalyst systems, preferably catalyst systems that are incompatible with each other. In particular, the processes relate to transitioning from olefin polymerizations utilizing metallocene catalyst systems to olefin polymerizations utilizing traditional Ziegler-Natta catalyst systems.

Abstract: Embodiments of the present invention relate to measuring and controlling static in a gas phase reactor polymerization. In particular, embodiments relate to monitoring carryover static in an entrainment zone during gas phase polymerization to determine the onset of reactor discontinuity events such as chunking and sheeting. Embodiments also relate to monitoring carryover static to determine the need for effective additions of continuity additives that minimize reactor static activity and thereby preventing discontinuity events.