Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: External donor systems, catalyst systems and olefin polymerization processes are described herein. The external donor systems generally include a first external donor represented by the general formula SiR2m(OR3)4-m, wherein each R2 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R3 is independently selected from alkyls and m is from 0 to 4. The external donor systems further include a second external donor represented by the general formula SiR4m(OR5)4-m, wherein each R4 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R5 is independently selected from alkyls, m is from 0 to 4 and at least one R4 is a C3 or greater alkyl.

Abstract: A method comprising preparing a multi-component catalyst system comprising a catalyst and a cocatalyst, and adjusting the level of at least one component of the catalyst system to maintain a user-desired level of catalyst activity throughout a process, wherein the component comprises a catalyst activator and wherein the catalyst activator comprises the catalyst or the cocatalyst. A method comprising contacting a polymerization catalyst system comprising a Ziegler-Natta catalyst and a cocatalyst with a catalyst activator at least twice during a polymerization process, wherein the polymerization process is carried out in a reactor system comprising multiple reactor types.

Abstract: External donor systems, catalyst systems and olefin polymerization processes are described herein. The external donor systems generally include a first external donor represented by the general formula SiR2m(OR3)4-m, wherein each R2 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R3 is independently selected from alkyls and m is from 0 to 4. The external donor systems further include a second external donor represented by the general formula SiR4m(OR5)4-m, wherein each R4 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R5 is independently selected from alkyls, m is from 0 to 4 and at least one R4 is a C3 or greater alkyl.

Abstract: External donor systems, catalyst systems and olefin polymerization processes are described herein. The external donor systems generally include a first external donor represented by the general formula SiR2m(OR3)4-m, wherein each R2 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R3 is independently selected from alkyls and m is from 0 to 4. The external donor systems further include a second external donor represented by the general formula SiR4m(OR5)4-m, wherein each R4 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R5 is independently selected from alkyls, m is from 0 to 4 and at least one R4 is a C3 or greater alkyl.

Abstract: External donor systems, catalyst systems and olefin polymerization processes are described herein. The external donor systems generally include a first external donor represented by the general formula SiR2m(OR3)4-m, wherein each R2 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R3 is independently selected from alkyls and m is from 0 to 4. The external donor systems further include a second external donor represented by the general formula SiR4m(OR5)4-m, wherein each R4 is independently selected from alkyls, cycloalkyls, aryls and vinyls, each R5 is independently selected from alkyls, m is from 0 to 4 and at least one R4 is a C3 or greater alkyl.

Abstract: A monomer stream containing propylene is supplied to a polymerization reactor which is operated under temperature and pressure conditions effective for the production of a stereoregular propylene polymer fluff. A titanium-based supported Ziegler-Natta catalyst having a titanium content of at least 1.7 wt. % and incorporating an internal electron donor is incorporated into the monomer stream. A trialkylaluminum co-catalyst is supplied to the monomer stream in an amount to provide an aluminum/titanium molar ratio within the range of 50-500. A silicon-based external electron donor is also supplied to the monomer stream in an amount to provide an aluminum/silicon molar ratio within the range of 10-500. Polymer fluff recovered from the polymerization reactor has a melt flow rate of at least 200 grams/10 minutes, and a xylene soluble content of no more than 4 wt. %.

Abstract: Processes for the formulation of Ziegler-type catalysts from a plurality of catalyst components including transition metal, organosilicon electron donor, and organoaluminum co-catalyst components. The components are mixed together in the course of formulating the Ziegler-type catalyst to be charged to an olefin polymerization reactor. Several orders of addition of the catalyst components can be used in formulating the Ziegler catalyst. One involves mixing of the transition metal component with the organoaluminum co-catalyst to formulate a mixture having an aluminum/transition metal mole ratio of at least 200. This mixture is combined with the organosilicon electron donor component to produce a Ziegler-type catalyst formulation having an aluminum/silicon mole ratio of no more than 50. There may be an initial pre-polymerization of the catalyst prior to introducing the catalyst into an olefin polymerization reactor.

Abstract: Processes for the polymerization of olefins with Zeigler-type catalyst systems which involve transition metal catalyst components comprising 4, 5 or 6 transition metals incorporating internal electron donors to provide desired polymerization characteristics, including yield and polymer characteristics. Specific olefins used in the polymerization process are C2-C4 alpha olefins such as propylene in the production of stereoregular polypropylene. The catalyst system comprised a transition metal component having an internal electron donor in an amount providing an internal donor/transition metal mole ratio of no more than 2/3. This is combined with an organoaluminum co-catalyst component to provide a precusor mixture having an aluminum/transition metal mole ration of at least 100. The precusor mixture is combined with an organosilicon external electron donor component in an amount to provide an aluminum/silicon mole ration of no more than 200.

Abstract: Processes for the formulation of Ziegler-type catalysts from a transition metal component, an electron donor and a co-catalyst which are sequentially mixed together. The co-catalyst is initially contacted with either of the transition metal catalyst or the electron donor for a first contact time of 5-120 seconds. This mixture is then contacted with the remainder of the electron donor or transition metal component for a second contact time of less and 110 seconds. The three component system is then used in olefin polymerization. The olefin contacting step can involve an initial pre-polymerization reaction. A specific order of addition involves mixture of the transition metal component and the co-catalyst component for a contact time of 5-120 seconds followed by contact with an electron donor component for no more than 30 seconds. Another order of addition involves initially contacting the electron donor with the co-catalyst.

Abstract: The present invention provides a composition and a process wherein a metallocene catalyst is dissolved in an alumoxane which has been dissolved in a solvent to form a concentrated stock solution of metallocene-alumoxane which can be stored for at least 14 days. The metallocene-alumoxane solution is stored under an oxygen- and water-free environment and more preferably under argon at temperatures that can range from about 25 degrees Fahrenheit (-4 degrees C.) to about 85 degrees Fahrenheit (29 degrees C.). Before or at the time that the metallocene-alumoxane solution is injected into the reactor, it is diluted with a second solution comprised of either an alumoxane, an aluminum alkyl or mixtures thereof dissolved in an oleaginous solvent. The addition of the aluminum based co-catalyst serves a two fold purpose.

Abstract: A system for combining the components of a multi-component catalyst system comprising at least four chambers with flow passageway means connecting the chambers in series. The catalyst components can include a transition metal, an electron donor and a co-catalyst, which are sequentially mixed together in the course of formulating a Ziegler-type system to be charged to an olefin polymerization reactor. The passages between the second and third chambers have valves. Each of the second and fourth chambers is provided with an inlet opening separate from the interconnecting flow passages and a vent opening separate from the inlet openings and the interconnecting flow passages. The chamber also has an outlet opening. This system also has flushing inlet passages for each of the four chambers which are connected to a manifold adapted to be connected to a source of nitrogen.

Abstract: This invention relates to a catalyst system using a boron alkyl in combination with an aluminum alkyl as a co-catalyst, a process for making the catalyst system and a process using the catalyst system for polymerization of olefins, especially .alpha.-olefins, such as propylene. While both boron alkyls and aluminum alkyls are known as co-catalysts separately, use of a boron alkyl with an aluminum alkyl as co-catalysts in olefin polymerization resulted in an unexpected increase in polymer yield. An increase in yield is accomplished without any increase in the amount of aluminum residue in the polymer product. The preferred boron alkyl is triethyl boron. The preferred aluminum alkyl is TEAl.

Abstract: This invention relates to a catalyst system using a diethylaluminum alkoxide-aluminum alkyl cocatalyst and to a process for polymerization of olefins using the catalyst system. Use of this catalyst system increases polymerization yield. The diethylaluminum alkoxide is preferably diethylaluminum ethoxide and the aluminum alkyl is preferably triethyl aluminum. The mole-to-mole ratio of diethylaluminum alkoxide to aluminum alkyl ranges from 0.05 to 0.2. This invention is effective for the aluminum/transition metal ratio for the polymerization of olefins ranges from about 100 to about 500. Polymerization yield increases of greater than 10% are realized.