Abstract: A process for preparing a catalyst comprising (A) selecting a catalyst support selected from the group consisting of gels of silica, silica alumina, alumina, aluminum phosphate, aluminaphospate, and combinations of two or more thereof; (B) mixing the catalyst support with one or more chromium containing compound, wherein the chromium containing compound is selected from the group consisting of chromium containing compounds which are oxidizable to a Cr+6 state and chromium containing compounds wherein the chromium is in a Cr+6 state; (C) mixing the catalyst support with one or more transition metal catalyst component; (D) calcining the catalyst support; and (E) optionally for the chromium containing compound which is oxidizable to a Cr+6 state, converting the chromium in the chromium containing compound to Cr+6; and (F) spray drying the catalyst support to form catalyst particles; wherein steps (B)-(F) may occur separately in any order or wherein any one or more of steps (B)-(F) may be combined together; and w

Abstract: The invention provides an ethylene-based interpolymer comprising the following features: a) density from 0.910 to 0.930 g/cc; b) melt index (I2) from 0.1 to 0.5 g/10 min; and c) a high density fraction in an ATREF short chain branch distribution (SCBD) curve, eluting above 92° C., of greater than 10 percent to less than 28 percent of the total ATREF SCBD curve area. The invention also provides a composition comprising an ethylene-based interpolymer that comprises the following features: a) a density from 0.919 to 0.928 g/cc; b) a melt index (I2) from 0.1 to 0.8 g/10 min; and c) a high density fraction in an ATREF short chain branch distribution (SCBD) curve, eluting above 92° C., of greater than 10 percent to less than 28 percent of the total ATREF SCBD curve area. The invention also provides a hollow tube comprising at least one component formed from a composition comprising an ethylene-based interpolymer that comprises the following features: a) a density from 0.919 to 0.

Abstract: A process for preparing a catalyst, and catalysts prepared thereby. The process includes selecting a catalyst support and mixing it with one or more chromium containing compounds oxidizable to a Cr+6 state or already in a Cr+6 state, and with one or more transition metal catalyst component, and calcining the catalyst support while oxidizing any chromium containing compound to a Cr+6 state, and spray drying the catalyst support to form catalyst particles. The catalyst supports are characterized by a surface area greater than 50 m2/gram and a pore volume greater than 0.5 cc/gram at the time of mixing the catalyst support with the chromium containing compound.

Abstract: A process for preparing a catalyst, and catalysts prepared thereby. The process includes selecting a catalyst support and mixing it with one or more chromium containing compounds oxidizable to a Cr+6 state or already in a Cr+6 state, and with with one or more transition metal catalyst component, and calcining the catalyst support while oxidizing any chromium containing compound to a Cr+6 state, and spray drying the catalyst support to form catalyst particles. The catalyst supports are characterized by a surface area greater than 50 m2/gram and a pore volume greater than 0.5 cc/gram at the time of mixing the catalyst support gels with the chromium containing compound.

Abstract: A spray-dried composition comprising the reaction product of a magnesium halide, a solvent, an electron donor compound, and a transition metal compound and an inert filler comprising substantially spherical particles having an average particle size ranging from about 1 ?m to about 12 ?m, and a polymerization process using the same.

Abstract: A spray-dried catalyst precursor composition and method of making a spray-dried catalyst precursor composition with an inert filler, magnesium, a transition metal, solvent, and one electron donor compound. The catalyst precursor composition is substantially free of other electron donor compounds, the molar ratio of the electron donor compound to magnesium is less than or equal to 1.9, and comprises spherical or substantially spherical particles having a particle size of from about 10 to about 200 ?m. Catalysts made from the spray-dried catalyst precursors and polymerization methods using such catalysts are disclosed.

Abstract: A spray-dried composition comprising the reaction product of a magnesium halide, a solvent, an electron donor compound, and a transition metal compound and an inert filler comprising substantially spherical particles having an average particle size ranging from about 1 &mgr;m to about 12 &mgr;m, and a polymerization process using the same.

Abstract: A method of making a spray-dried composition using a solution or mixture comprising the reaction product of a magnesium halide, a solvent, an electron donor compound, and a transition metal compound and an inert filler comprising substantially spherical particles having an average particle size ranging from 1 &mgr;m to about 12 &mgr;m.

Abstract: A magnesium halide composition comprising and/or made from a magnesium halide, a solvent suitable for an electron donor compound and an electron donor compound. The composition is characterized by enhanced solubility whereby it has a solubility in the solvent that does not decrease as a function of temperature up to the boiling point of the solvent and the solubility of the magnesium halide in the solvent is greater than 0.7 mol/liter. A polymerization catalyst precursor composition can be made from magnesium halide composition by mixing the magnesium halide composition with a transition metal compound.

Abstract: A method for increasing the solubility of a magnesium halide includes providing an electron donating solvent, contacting a magnesium halide with the solvent; and providing an electron donor compound to form a magnesium halide composition. The composition is characterized by a solubility in the electron donor solvent that does not decrease up to the boiling point of the solvent. A polymerization catalyst precursor composition comprises the product of mixing the magnesium halide composition with a transition metal compound. Active catalysts prepared from such precursors and a methods of polymerization using such catalysts are also disclosed.

Abstract: A spray-dried composition comprising an inert porous filler and a reaction product of 1) a mixture or reaction product of a magnesium halide, a solvent, an electron donor compound, and a transition metal compound. The filler is substantially spherical and has an average particle size ranging from about 1 &mgr;m to about 12 &mgr;m. Methods of making spray-dried compositions, catalysts and polymerization processes employing such are also described.

Abstract: A spray-dried catalyst precursor composition and method of making a spray-dried catalyst precursor composition with an inert filler, magnesium, a transition metal, solvent, and one electron donor compound. The catalyst precursor composition is substantially free of other electron donor compounds, the molar ratio of the electron donor compound to magnesium is less than or equal to 1.9, and comprises spherical or substantially spherical particles having a particle size of from about 10 to about 200 &mgr;m. Catalysts made from the spray-dried catalyst precursors and polymerization methods using such catalysts are disclosed.

Abstract: A process of polymerizing ethylene or ethylene and one or more comonomers in one or more fluidized bed reactors with a catalyst system comprising (i) a supported or unsupported magnesium/titanium based precursor in slurry form, said precursor containing an electron donor; and (ii) an activator containing aluminum in an amount sufficient to essentially complete the activation of the precursor is disclosed. In the process, the precursor and the activator are mixed prior to introduction into the reactor in at least one mixing procedure, and then the mixture is contacted again with additional activator to essentially complete activation of the precursor. In the method, the atomic ratio of aluminum to titanium is in the range of about 1:1 to about 15:1 and the mole ratio of activator to electron donor is about 1:1 to about 2:1, and no additional activator is introduced into the reactor(s).

Abstract: In a process for the in situ blending of polymers comprising contacting ethylene and one or more comonomers in two or more fluidized bed reactors with a catalyst system comprising (i) a magnesium/titanium based precursor containing an electron donor and (ii) a hydrocarbyl aluminum cocatalyst, the improvement comprising (A) increasing or decreasing the melt flow ratio and/or molecular weight of the blend by, respectively, decreasing or increasing the mole ratio of a precursor activator compound to the electron donor or (B) increasing or decreasing the bulk density of the blend by, respectively, increasing or decreasing the mole ratio of a precursor activator compound to the electron donor, both (A) and (B) subject to defined provisos including partial pre-activation of the precursor.

Abstract: The invention teaches a novel design for a fluidized bed polymerization reactor which utilizes a primary fluidization grid to provide mixing and fluidization of the polymer and at least one secondary distribution plate located above the first distribution plate to promote segregation of polymer particles by size, the larger particles falling into the lower fluidization zone and the smaller particles being entrained up from the primary fluidization grid and through the secondary distribution grid into an upper reaction zone.

Abstract: The invention teaches a novel design for a fluidized bed polymerization reactor which utilizes a primary fluidization grid to provide mixing and fluidization of the polymer and at least one secondary distribution plate located above the first distribution plate to promote segregation of polymer particles by size, the larger particles falling into the lower fluidization zone and the smaller particles being entrained up from the primary fluidization grid and through the secondary distribution grid into an upper reaction zone.

Abstract: A process is provided for preparing a shape-shifted catalyst component comprising (1) contacting a dihydrocarbyloxide magnesium compound with carbon dioxide in the presence of a slurrying agent to form a slurry of a carboxylated dihydrocarbyloxide magnesium compound; (2) adding a filler to the slurry either before or after the carboxylation of step (1); (3) spray drying the slurry of step (2) to evaporate the slurrying agent and to produce solid particles of the carboxylated dihydrocarbyloxide magnesium compound incorporating the filler; and, optionally, (4) heating the solid particles to remove carbon dioxide to produce a shape-shifted dihydrocarbyloxide magnesium compound component. A catalyst system using the component and a polymerization process employing the catalyst system are also provided.