Abstract: Methods of preparing bimetallic catalysts are disclosed. The methods include the steps of providing a supported non-metallocene catalyst, contacting a slurry of the supported non-metallocene catalyst in a non-polar hydrocarbon with a solution of a metallocene compound and an alumoxane, and drying the contact product to obtain a supported bimetallic catalyst. The supported non-metallocene catalyst is prepared by dehydrating a particulate support material at a temperature of greater than 600° C., preparing a slurry of the dehydrated support in a non-polar hydrocarbon, contacting the slurry with an organomagnesium compound and an alcohol, contacting the resulting slurry with a non-metallocene compound of a Group 4 or Group 5 transition metal, and drying the contact product to obtain a supported non-metallocene catalyst as a free-flowing powder. The bimetallic catalysts show increased activity relative to catalysts prepared using support materials dehydrated at lower temperatures.

Abstract: The invention relates to a process for uniformly dispersing a transition metal metallocene complex on a carrier comprising (1) providing silica which is porous and has a particle size of 1 to 250 microns, having pores which have an average diameter of 50 to 500 Angstroms and having a pore volume of 0.5 to 5.0 cc/g; (2) slurrying the silica in an aliphatic solvent having a boiling point less than 110° C.

Abstract: A method is disclosed for preparing broad or bimodal molecular weight distribution polyolefins having a targeted property, such as, flow index, melt flow ratio, or weight fractions of higher or lower molecular weight components. The method uses a bimetallic catalyst containing a metallocene component and a non-metallocene component, and the activities of the metallocene and non-metallocene portions are controlled by adjusting the ratio of organoaluminum and modified methylaluminoxane cocatalyst. The method allows for monitoring and adjustment of polyolefin properties on a real-time basis, as the polyolefin is forming.

Abstract: Methods of preparing bimetallic catalysts are disclosed. The methods include the steps of providing a supported non-metallocene catalyst, contacting a slurry of the supported non-metallocene catalyst in a non-polar hydrocarbon with a solution of a metallocene compound and an alumoxane, and drying the contact product to obtain a supported bimetallic catalyst. The supported non-metallocene catalyst is prepared by dehydrating a particulate support material at a temperature of greater than 600° C., preparing a slurry of the dehydrated support in a non-polar hydrocarbon, contacting the slurry with an organomagnesium compound and an alcohol, contacting the resulting slurry with a non-metallocene compound of a Group 4 or Group 5 transition metal, and drying the contact product to obtain a supported non-metallocene catalyst as a free-flowing powder. The bimetallic catalysts show increased activity relative to catalysts prepared using support materials dehydrated at lower temperatures.

Abstract: A process of forming a bimetallic catalyst composition comprising a cocatalyst (a trialkylaluminum compound) and a catalyst precursor. The precursor comprises at least two transition metals; a metallocene complex is a source of one of said two transition metals. The precursor is produced in a single-pot process by contacting a porous carrier, in sequence, with a dialkylmagnesium compound, an aliphatic alcohol, a non-metallocene transition metal compound, a contact product of a metallocene complex and a trialkyl-aluminum compound, and methylalumoxane.

Abstract: A process of forming a bimetallic catalyst composition comprising a cocatalyst (a trialkylaluminum compound) and a catalyst precursor. The precursor comprises at least two transition metals; a metallocene complex is a source of one of said two transition metals. The precursor is produced in a single-pot process by contacting a porous carrier, in sequence, with a dialkylmagnesium compound, an aliphatic alcohol, a non-metallocene transition metal compound, a contact product of a metallocene complex and a trialkyl-aluminum compound, and methylalumoxane.

Abstract: A process for controlling the MWD of a broad or bimodal resin in a single fluid bed reactor using a mixed catalyst composition containing a bimetallic catalyst and a make-up catalyst of at least one metallic component of the bimetallic catalyst. The bimetallic catalyst, which is formed with at least one metallocene of a transition metal, produces broad or bimodal molecular weight distribution polyolefin resin whose composition depends on the ratio of the concentration of the two catalyst components producing the HMW/LMW components. The make-up catalyst consisting of a single metal component is added in proportion necessary to make-up the deficiencies in the amount of the HMW/LMW component. The type of make-up catalyst added depends on whether increase of the HMW or LMW component produced by the bimetallic catalyst is sought. The mixed catalyst compostion may be fed into the reactor as a mixture or through separate catalyst ports of the reactor.

Abstract: A process of forming a bimetallic catalyst composition comprising a cocatalyst (a trialkylaluminum compound) and a catalyst precursor. The precursor comprises at least two transition metals; a metallocene complex is a source of one of said two transition metals. The precursor is produced in a single-pot process by contacting a porous carrier, in sequence, with a dialkylmagnesium compound, an aliphatic alcohol, a non-metallocene transition metal compound, a contact product of a metallocene complex and a trialkyl-aluminum compound, and methylalumoxane.

Abstract: A process of forming a bimetallic catalyst composition comprising a cocatalyst (a trialkylaluminum compound) and a catalyst precursor. The precursor comprises at least two transition metals; a metallocene complex is a source of one of said two transition metals. The precursor is produced in a single-pot process by contacting a porous carrier, in sequence, with a dialkylmagnesium compound, an aliphatic alcohol, a non-metallocene transition metal compound, a contact product of a metallocene complex and a trialkyl-aluminum compound, and methylalumoxane.

Abstract: The invention relates to a process for uniformly dispersing a transition metal metallocene complex on a carrier comprising

Abstract: The invention relates to a process for uniformly dispersing a transition metal metallocene complex on a carrier comprising (1) providing silica which is porous and has a particle size of 1 to 250 microns, having pores which have an average diameter of 50 to 500 Angstroms and having a pore volume of 0.5 to 5.0 cc/g; (2) slurrying the silica in an aliphatic solvent having a boiling point less than 110° C.; (3) providing a volume of a solution comprising metallocene and alumoxane wherein the volume of solution is less than that required to form a slurry of the silica, wherein the concentration of alumoxane, expressed as Al weight percent, is 5 to 20; (4) contacting the silica slurry (2) with said volume of said solution (3) and allowing the solution to impregnate the pores of silica and, to disperse the metallocene in and on the carrier; (5) evaporating the solvents from the contacted and impregnated silica to recover dry free-flowing catalyst particles.

Abstract: A process for controlling the MWD of a broad or bimodal resin in a single fluid bed reactor using a mixed catalyst composition containing a bimetallic catalyst and a make-up catalyst of at least one metallic component of the bimetallic catalyst. The bimetallic catalyst, which is formed with at least one metallocene of a transition metal, produces broad or bimodal molecular weight distribution polyolefin resin whose composition depends on the ratio of the concentration of the two catalyst components producing the HMW/LMW components. The make-up catalyst consisting of a single metal component is added in proportion necessary to make-up the deficiencies in the amount of the HMW/LMW component. The type of make-up catalyst added depends on whether increase of the HMW or LMW component produced by the bimetallic catalyst is sought. The mixed catalyst compostion may be fed into the reactor as a mixture or through separate catalyst ports of the reactor.

Abstract: A make-up catalyst of at least one metallic component of a bimetallic catalyst component is used in conjunction with a bimetallic catalyst to control the proportion of weight fractions in broad or bimodal molecular weight distribution olefin resin product. The bimetallic catalyst produces broad or bimodal molecular weight distribution polyolefin resin whose composition depends on the ratio of the concentration of the two catalyst components producing the HMW/LMW components. The make-up catalyst consisting of a single metal component is added in proportion necessary to make-up the deficiencies in the amount of the HMW/LMW component. The type of make-up catalyst added depends on whether increase of the HMW or LMW component produced by te bimetallic catalyst is sought.

Abstract: A catalyst composition for the polymerization of one or more 1-olefins (e.g., ethylene) comprises a transition metal catalyst precursor and a cocatalyst, the transition metal catalyst precursor comprising a contact product of an unsubstituted metallocene compound and an aluminum alkyl compound in a hydrocarbon solvent solution. In another embodiment, the transition metal catalyst precursor is bimetallic and contains a non-metallocene transition metal catalyst component. When a bimetallic catalyst precursor is used, the resin product exhibits improved properties, and has a bimodal molecular weight distribution, long chain branching (LCB), and good bubble stability.

Abstract: A process of forming a bimetallic catalyst composition comprising a cocatalyst (a trialkylaluminum compound) and a catalyst precursor. The precursor comprises at least two transition metals; a metallocene complex is a source of one of said two transition metals. The precursor is produced in a single-pot process by contacting a porous carrier, in sequence, with a dialkylmagnesium compound, an aliphatic alcohol, a non-metallocene transition metal compound, a contact product of a metallocene complex and a trialkylaluminum compound, and methylalumoxane.

Abstract: A make-up catalyst of at least one metallic component of a bimetallic catalyst component is used in conjunction with a bimetallic catalyst to control the proportion of weight fractions in broad or bimodal molecular weight distribution olefin resin product. The bimetallic catalyst which is formed with at least one metallocene of a transition metal, produces broad or bimodal molecular weight distribution polyolefin resin whose composition depends on the ratio of the concentration of the two catalyst components producing the HMW/LMW components. The make-up catalyst consisting of a single metal component is added in proportion necessary to make-up the deficiencies in the amount of the HMW/LMW component. The type of make-up catalyst added depends on whether increase of the HMW or LMW component produced by the bimetallic catalyst is sought.

Abstract: An ethylene-alpha-olefin copolymerization catalyst is prepared by impregnating a silica calcined at elevated temperature sequentially with an organomagnesium compound such as dialkylmagnesium compound, a silane compound which is free of hydroxyl groups, such as tetraethyl orthosilicate. A transition metal component such as titanium tetrachloride is then incorporated into the support. Unexpectedly, the calcination temperature of the silica used to prepare the catalyst precursors has a strong influence on polymer product properties. By increasing the calcination temperature of the silica from 600° to 700° C. or higher temperatures, a catalyst precursor when activated produced ethylene/1-hexene copolymers with narrower molecular weight distributions (MWD) as manifested by a decrease of resin MFR values of ˜3-4 units. Activation of this catalyst precursor with a trialkylaluminum compound results in a catalyst system which is effective for the production of ethylene copolymers.

Abstract: A class of relatively high molecular weight, high density ethylene polymer blends is disclosed capable of being blow molded with excellent processability into articles, e.g., bottles, of superior mechanical and other properties, such blends having a density of at least about 0.930 g/cc, a flow index (I21) of at least about 2 g/10 min., a melt flow ratio (MFR) of at least about 60, and a polydispersity index of at least about 8, the polymers of said blend consisting essentially of at least about 0.3 weight fraction of a relatively high molecular weight (HMW) component having a density of at least about 0.900 g/cc, a flow index or high load melt index (I21) of at least about 0.2 g/10 min., and a flow ratio (FR) at least about 10, and a relatively low molecular weight (LMW) component having a density of at least about 0.930 g/cc and a melt index (I2) no greater than about 1000 g/10 min.

Abstract: Catalyst compositions for homopolymerization and copolymerization of ethylene which comprise two transition metal compounds, one of them a cyclopentadienyl complex of a transition metal and another a non-metallocene derivative of a transition metal are described. The catalysts are activated by alkylalumoxanes that are soluble in non-aromatic hydrocarbons. Bimetallic catalysts of this invention are suitable for the manufacture of ethylene homopolymers and copolymers with broad bimodal molecular weight distributions. The alkyl alumoxanes have at least one [AR(R)--O--] repeating group in which R is an alkyl group of at least two carbon atoms.

Abstract: The present invention provides cocatalysts for activating metallocene complexes in olefin polymerization reactions, and metallocene catalyst systems using the cocatalysts. The cocatalysts of the present invention include: (a) a halo-organoaluminum compound of the formula AlnRmX3n-m, where Al is aluminum, each R is independently a Cl to C4 alkyl group, X is a halide, n is 1 or 2, and m is determined by the valency of Al; and (b) a dialkylmagnesium compound of the formula MgR′2, where Mg is magnesium and R′ is a C2 to C6 alkyl group. The components (a) and (b) are used in amounts such that the molar ratio of Al:Mg is at least 2, preferably from 2:1 to 5:1.