Abstract: The present invention relates to a process for manufacturing polyolefin polymerization catalysts and provides a process for manufacturing polyolefin polymerization catalysts, wherein after manufacturing a homogeneous solution of magnesium compounds using magnesium compounds and alcohols along with hydrocarbon solvents and contacting with titanium compounds by adding organic aluminum, the mixture is treated again with organic aluminum or alcohols having 5 or less carbon atoms, then contacted with titanium compounds. Polyolefin polymerization catalysts prepared by the preparation process of the present invention have superior polyolefin polymerization activities, they prepare polymers having high Melt Flow Ratios, and produce a lesser amount of fine particle polymers.

Abstract: The present invention relates to a method for producing a polymer and copolymer of ethylene, and more particularly to a method for producing an ethylene polymer and copolymer by reacting a compound of an organic metal of Group 2, 12, or 13 on the periodic table of elements with an alkoxy silane compound in the presence of a titanium catalyst, the said titanium catalyst being produced by a process of preparing a magnesium compound by contact-reacting a halogenated magnesium compound and alcohol, of reacting the said solution with an ester compound which contains at least one hydroxy group and a silicon compound containing an alkoxy group, and also of reacting it with a solid matter obtained by reaction of a mixture of a titanium compound and a silicon compound with a titanium compound.

Abstract: A process is provided for preparing a catalyst support for polymerizing &agr;-olefins comprising the steps of: (i) reacting, in the presence of a first electron donor, a chlorine-containing organic compound and a prior mixture of an alkylmagnesien and an aluminoxane and/or aluminosiloxane and/or alkylaluminum and, optionally, a second electron donor; and (ii) activating a product from step (i) in suspension in an inert liquid by means of an activation electron donor, together with the support thus obtained, a catalyst for polymerizing &agr;-olefins, comprising this catalyst support and a group IV transition metal halide, and a process for polymerizing &agr;-olefins, particularly propylene, comprising contacting the &agr;-olefin with the catalyst.

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 present invention relates to a solid complex titanium catalyst for homo-polymerization and co-polymerization of &agr;-olefin, obtained by (i) producing a solution of a magnesium compound by dissolving a magnesium compound and a compound of IIIA Group of the Periodic Table in a solvent mixed with cyclic ether, one or more types of alcohol, a phosphorous compound, and an organosilane, (ii) precipitating the solid particles by reacting said magnesium solution with a compound of a transition metal, a silicon compound, or the mixture thereof, and (iii) reacting said precipitated solid particles with a titanium compound and an electron donor. The catalyst of the present invention is of large particle size, narrow particle distribution, and high catalytic activity, while the polymers obtained with the use of this catalyst are of excellent stereoregularity.

Abstract: Olefin polymers produced using components of catalysts obtained by contacting a Ti compound of formula Ti(OR)n-yXy, where n is the valence of titanium and y is a number between 1 and n, with a pre-polymer having a porosity higher than 0.3 cc/g and containing from 0.5 to 100 g of polymer per g of solid catalyst component, the pre-polymer being obtained by (co)polymerizing an olefin or a diolefin in the presence of a catalyst comprising a Ti, V, Zr or Hf compound supported on a Mg dihalide having a mean crystallite dimension lower than 30 nm.

Abstract: A process of forming a polyolefin catalyst component includes contacting a metal compound of the formula MR2 with a diketone to form a metal bis(diketonate) having the formula M(OCRCR′CRO)2, wherein M is a Group IIA or Group VIIB metal, and wherein R and R′ are each hydrocarbyls or substituted hydrocarbyls having from 1 to 20 carbons atoms. Catalyst components, catalysts, polyolefin polymers, catalysts systems, and methods of preparing same are disclosed.

Abstract: The invention relates to a magnesium compound effective in producing olefin polymers having an increased bulk density and a narrowed particle size distribution, not lowering the stereospecificity of the polymers produced and not lowering the polymerization activity in producing the polymers, to an olefin polymerization catalyst comprising the compound, and to a method for producing such olefin polymers. The olefin polymerization catalyst comprises (A) a solid catalyst component prepared by contacting a magnesium compound having a specific particle size distribution index (P), a titanium compound and an electron donor compound with each other, (B) an organometallic compound, and (C) an electron donor. The olefin polymerization method comprises polymerizing an olefin in the presence of the catalyst to give olefin polymers.

Abstract: Disclosed are catalysts for the polymerization of alpha-olefins which comprise the reaction product of: (a) an Al-alkyl compound; (b) a silicon compound containing at least one Si—OR or Si—OCOR or Si—NR2 bond, R being a hydrocarbyl radical; (c) a solid comprising, as essential support, a Mg dihalide in active form and, supported thereon, a Ti halide or a halo-Ti-alcoholate and a particular type of electron donor compound. The present invention refers to new supported components of catalysts for the polymerization of CH2═CHR olefins wherein R is an alkyl radical with 1 to 4 carbon atoms, or an aryl radical, and mixtures of said olefins with ethylene and the catalysts obtained from said components.

Abstract: Disclosed is a new titanium based catalyst system for (co)-polymerizing ethylene or ethylene with alpha-olefin having 3 to 10 carbons. The catalyst is obtained by contacting a magnesium halide support with an aluminum compound and with a titanium halide compound and then treating the resulting solid with a magnesium-amide complex. The catalyst system is suitable for producing ethylene polymer and co-polymer with narrow molecular weight distribution as well as improved branching compositional distribution.

Abstract: A magnesium halide support material for a polyolefin catalysts is disclosed. The magnesium halide of present invention is prepared by reacting magnesium with an alkylhalide in a non-polar hydrocarbon solvent. Preparation of the support does not require the use electron donating solvents and therefore does not require extensive washing to remove the solvent from the support.

Abstract: A process is provided for the preparation of a solid catalyst component for the polymerization of olefins, comprising continuously feeding a liquid containing a titanium compound having at least one titanium-halogen bond into a vessel containing a solid comprising a magnesium halide and continuously discharging liquid from the vessel, whereby the concentration of the solid is maintained within the range of between 80 and 300 g/l, and the product between the average residence time of the liquid in the vessel and the concentration of the solid is maintained below 10,000 min*g/l. An advantage of the process is the reduced time and reactor volume necessary to prepare the catalysts, which show good activity and stereospecificity.

Abstract: A supported catalyst composition comprising the reaction product of i) a magnesium halide, ii) a solvent, iii) an electron donor compound, iv) and a transition metal compound; an inert support; and a cocatalyst composition wherein the supported catalyst is substantially free of other alcohols and wherein the molar ratio of the first alcohol to magnesium is less than or equal to 1.9. Methods of making supported catalyst compositions and methods of making polymers with supported catalysts.

Abstract: The invention provides a catalyst component for ethylene polymerization, comprising an inorganic oxide support, and at least one alkyl metal compound, at least one halide, at least one dihydrocarbyl magnesium compound, at least one difuntional compound that reacts with the dihydrocarbyl magnesium compound and at least one titanium compound. The invention also relates to a process for preparing the catalyst component and use thereof. The catalyst comprising the catalyst component exhibits good hydrogen response and activity balance, and that the amount of static charges carried by the catalyst solid component powders is remarkably reduced will facilitate the industrial-scale operation of polymerization.

Abstract: The present invention provides a method for producing a new catalyst of high polymerization activity for homo- or co-polymerization of ethylene, or more particularly a method for producing a titanium solid complex catalyst supported on a carrier containing magnesium, wherein said catalyst is capable of producing polymers of high bulk density and narrow particle size distribution with few fine particles.

Abstract: The present invention relates to a catalyst composition for polymerization of olefins comprising: (a) a solid catalyst pre cursor comprising at least one vanadium compound, at least one magnesium compound and a polymeric material or a solid catalyst precursor comprising at least one vanadium compound, at least one further transition metal compound and/or at least one alcohol, at least one magnesium compound and a polymeric material; and (b) a cocatalyst comprising at least one aluminum compound; and to a method for preparing a catalyst composition according to the present invention, comprising the steps of: (a) combining the components of the solid catalyst precursor; and (b) activating the catalyst precursor with aluminum compound.

Abstract: A solid catalyst component for olefin polymerization comprising titanium, magnesium and a compound of the general formula (I) 1

Abstract: A new synthesis of a Ziegler-Natta catalyst uses a multi-step preparation that includes treating a magnesium dialkoxide compound with two halogenating/titanating agents, the second stronger than the first, an organoaluminum preactivating agent, and a heat treatment. The catalyst may be used in the polymerization of olefins, particularly ethylene, to control the molecular weight distribution of the resulting polyolefins.

Abstract: Olefin polymers with a broad molecular weight distribution can be obtained while maintaining the high stereoregularity of the polymers by polymerizing olefins using a catalyst comprising (A) a solid catalyst component prepared by contacting (a) a dialkoxymagnesium, (b) a tetravalent titanium halide compound, and (c) an electron donor compound one another, (B) an organoaluminum compound of the formula R1pAlQ3-p, and (C) an aminosilane compound of the formula R2R3Si(OR4)2.

Abstract: Process for the polymerization of olefins CH=CHR, in which R is hydrogen or a hydrocarbon radical with 1-12 carbon atoms, carried out in the presence of a catalyst component (A) comprising Mg, Ti and halogen as essential elements and of a catalyst component (B) capable to produce, under the same polymerization conditions, a polymer with an average particle size lower than that obtainable with the said catalyst component A. The said process provides polymers with increased bulk density.

Abstract: Bimetal catalyst for the (co)polymerization of &agr;-olefins comprising a co-catalyst consisting of a hydride or an organometallic compound of an element of groups 1, 2 or 13 of the periodic table, and a solid component consisting of at least 95% by weight of titanium, magnesium, hafnium, aluminum, chlorine and R—COO carboxylate groups, wherein R is an aliphatic, cycloaliphatic or aromatic hydrocarbon, containing from 1 to 30 carbon atoms, wherein at least 80% of the titanium is in oxidation state +3, and at least 1% of said titanium in oxidation state +3 has a tetrahedral coordination geometry. Said catalyst allows the production of olefinic polymers, particular polyethylene, with a high molecular weight by means of solution polymerization processes at temperatures exceeding 200° C.

Abstract: By controlling the hold up times, concentrations and temperatures for mixing the components of aluminum, titanium and magnesium based catalyst for solution polymerization it is possible to prepare a catalyst having a high activity, which prepares high molecular weight polyolefins. Generally, a catalyst loses activity and produces lower molecular weight polymer at higher temperatures. The catalyst of the present invention permits comparable polymers to be produced with higher catalyst activity and at higher reaction temperatures by increasing the concentration of the components used during the preparation of the catalyst.

Abstract: The present invention relates to a solid catalyst component for the polymerization of olefins CH2═CHR in which R is hydrogen or a hydrocarbon radical with 1-12 carbon atoms, comprising Mg, Ti, halogen and an electron donor selected from substituted succinates of a particular formula. Said catalyst components when used in the polymerization of olefins, and in particular of propylene, are capable to give polymers in high yields and with high isotactic index expressed in terms of high xylene insolubility.

Abstract: Disclosed is a preparation method of titanium catalyst for olefin polymerization, the method comprising (1) preparing magnesium compound solution by resolving non-deoxidative magnesium halide and IIIA group atom compound in a solvent mixture of cyclic ether, at least one alcohol, phosphorus compound and organosilane with or without hydrocarbon solvent; (2) reacting said magnesium compound solution with titanium compound, silicon compound, tin compound or mixture thereof to produce a support; and (3) reacting said support with titanium compound and electron donor to produce solid complex titanium catalyst, wherein the particle size and particle size distribution f said catalyst are regulated by controlling solubility of the reactants in said steps (2) and/or (3).

Abstract: The present invention relates to a method for the prepolymerization of &agr;-olefin in the presence of a catalyst system which comprises (a) a magnesium supported solid complex titanium catalyst and (b) an organometallic compound of metal of Group I or III of the Periodic Table, characterized in that an inert solvent having high viscosity with molecular weight of 300 g/mole or more is used as a reaction medium.

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 present invention provides an ethylene copolymer resin that has unique melt elastic properties not observed in ethylene copolymers heretofore known. Specifically, the ethylene copolymer resin of the present invention when in pelletized form has a reduction in melt elasticity (ER) of 10% or more to a final value of 1.0 or less upon rheometric low shear modification or solution dissolution. Moreover, the resin of the present invention when in reactor-made form exhibits at least a partially reversible increase of 10% or more in ER when pelletizing the same. An ethylene polymerization catalyst, a process of preparing the ethylene copolymer resin and a high-impact film are also provided herein.

Abstract: A Ziegler-Natta type catalyst component can be produced by a process comprising contacting a magnesium dialkoxide compound with a halogenating agent to form a reaction product A, and contacting reaction product A with a first, second and third halogenating/titanating agents. Catalyst components, catalysts, catalyst systems, polyolefin, products made therewith, and methods of forming each are disclosed. The reaction products can be washed with a hydrocarbon solvent to reduce titanium species [Ti] content to less than about 100 mmol/L.

Abstract: A process for making a polyolefin catalyst component, catalyst and polymer resin is disclosed. Controlling the viscosity of a catalyst synthesis solution with the addition of aluminum alkyl alters the precipitation of the catalyst component from a catalyst synthesis solution. The average particle size of the catalyst component increases with an increased concentration of aluminum alkyl in the synthesis solution. The catalyst component can be produced by a process comprising contacting a magnesium alkyl compound with an alcohol and an aluminum alkyl to form a magnesium dialkoxide. Catalyst components, catalysts, catalyst systems, polyolefin, products made therewith, and methods of forming each are disclosed. The reaction products can be washed with a hydrocarbon solvent to reduce titanium species [Ti] content to less than about 100 mmol/L.

Abstract: The present invention provides a method for producing a new catalyst of high catalytic activity and superior catalyst morphology for homo- or co-polymerization of ethylene, or more particularly a method for producing a titanium solid complex catalyst supported on a carrier containing magnesium, wherein said catalyst of high polymerization activity is capable of producing polymers of high bulk density.

Abstract: This process for preparing a catalyst support for the homopolymerization or copolymerization of ethylene and &agr;-olefins is characterized in that at least one organochlorine compound and a premix of at least one alkylmagnesium and of at least one organoaluminum compound chosen from aluminoxanes, aluminosiloxanes and alkylaluminums are reacted together, in the presence of at least one aliphatic diether as electron donor.

Abstract: The invention relates to a new process for the preparation of an olefin polymerization catalyst component, as well as a new polymerization catalyst component and its use. In the process, a magnesium dialkyl or diahlide or alkyl alkoxide is reacted with an alcohol and the reaction product is reacted with an unsaturated dicarboxylic acid dihalide and a titanium tetrahalide. Especially good catalyst activity and morphology are achieved by using a polyhydric alcohol such as ethylene glycol.

Abstract: Bimetallic catalyst for producing polyethylene resins with a bimodal molecular weight distribution, its preparation and use. The catalyst is obtainable by a process which includes contacting a support material with an organomagnesium component and carbonyl-containing component. The support material so treated is contacted with a non-metallocene transition metal component to obtain a catalyst intermediate, the latter being contacted with an aluminoxane component and a metallocene component. This catalyst may be further activated with, e.g., alkylaluminum cocatalyst, and contacted, under polymerization conditions, with ethylene and optionally one or more comonomers, to produce ethylene homo- or copolymers with a bimodal molecular weight distribution and improved resin swell properties in a single reactor. These ethylene polymers are particularly suitable for blow molding applications.

Abstract: A process (I) for producing an &agr;-olefin polymerization catalyst whereby (1) a titanium compound is reduced by an organomagnesium compound in the presence of an organosilicon compound to produce a reduction solid, (2) the reduction solid is aged to produce a solid product, (3) the solid product is contacted with an ether compound, titanium tetrachloride and an organic acid halide compound, to produce an organic acid halide-treated solid, (4) the organic acid halide-treated solid is contacted with a mixture of an ether compound, titanium tetrachloride and an ester compound, or with a mixture of an ether compound and titanium tetrachloride to produce a solid catalyst component containing a titanium compound, and (5) the solid catalyst component is contacted with an aluminum compound and an electron donor compound to produce a catalyst for &agr;-olefin polymerization. A process (II) for producing an &agr;-olefin polymer using a catalyst produced by process (I).

Abstract: A catalyst composition that is the combination of or the reaction product of ingredients comprising (a) an lanthanide compound, (b) an alkylating agent, (c) a nickel-containing compound, and optionally (d) a halogen-containing compound, with the proviso that the halogen-containing compound must be present where none of the lanthanide compound, the alkylating agent, and the nickel-containing compound contain a labile halogen atom.

Abstract: A method for making a solid catalyst component for use in a Ziegler-Natta catalyst includes combining a porous particulate support with a magnesium source in a hydrocarbon solvent to form a mixture, the magnesium source including a hydrocarbon soluble organomagnesium compound and a hydrocarbon insoluble anhydrous inorganic magnesium-halogen compound. The organomagnesium compound is halogenated and the mixture is reacted with a titanium compound or vanadium compound to form the solid catalyst component. The solid catalyst component is then recovered and combined with an organoaluminum cocatalyst to form a Ziegler-Natta catalyst which is advantageously used for the polymerization of olefins, particularly alk-1-enes such as ethylene, propylene, 1-butene, and the like. The catalyst can optionally include internal and external electron donors.

Abstract: Catalyst system for olefin polymerization comprising

Abstract: The present invention provides a catalyst system that exhibits unexpected control of desired properties in polyolefin products. The catalyst system includes a titanium-supported catalyst in combination with a mixture of tetraethoxysilane (TEOS) and dicyclopentyldimethoxy-silane (DCPMS). This catalyst system has been found to be effective in making polypropylene and polypropylene copolymers having relatively high melt flow rates and moderately broad molecular weight distribution.

Abstract: There are provided (1) a process for producing a solid product, which comprises the step of reducing a titanium compound represented by the following formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond, an inorganic fine particle and optionally an ester compound, (2) a process for producing a solid catalyst component, which comprises the step of contacting the solid product obtained by the above process, a halogenation ability-carrying halogeno compound, and an inner electron donor compound, (3) a process for producing a catalyst, which comprises the step of contacting the solid catalyst component obtained by the above process, an organoaluminum compound, and an outer electron donor compound, and (4) a process for producing an olefin polymer, which comprises the step of polymerizing an olefin in the presence of the catalyst obtained by the above process.

Abstract: Described herein is a prepolymerized catalyst encapsulated with macromolecular monomers which is prepared by adding olefin mononers and diene compounds to a solid complex titanium catalyst for olefin polymerization and then polymerizing, and also relates to a method for polymerization or copolymerization capable of preparing polyolefins with high melt strength by polymerizing the olefin by using said catalyst.

Abstract: Co-precipitated CoCuMn and CoCuMg catalysts are used in Fischer-Tropsch synthesis.

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 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: There are described a process for preparing catalyst components comprising vanadium, titanium, electron donor and magnesium chloride, supported or unsupported; catalyst systems incorporating the catalyst components; and the use of the catalyst systems in olefin polymerizations and interpolymerizations.

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: This invention provides catalyst compositions that are useful for polymerizing at least one monomer to produce a polymer. This invention also provides catalyst compositions that are useful for polymerizing at least one monomer to produce a polymer, wherein said catalyst composition comprises contacting an organometal compound, an organoaluminum compound, and a treated solid oxide compound.

Abstract: It has been discovered that using n-butylmethyldimethoxysilane (BMDS) as an external electron donor for Ziegler-Natta catalysts can provide a catalyst system that may prepare polypropylene films with improved properties. The catalyst systems of the invention provide for controlled chain defects/defect distribution and thus a regulated microtacticity. Consequently, the curve of storage modulus (G′) v. temperature is shifted such that the film achieves the same storage modulus at a lower temperature enabling faster throughput of polypropylene film through a high-speed tenter.

Abstract: This invention is based upon the unexpected discovery that certain catalyst systems which are comprised of (A) a transition metal compound selected from the group consisting of iron (II) compounds, iron (III) compounds, cobalt (II) compounds, cobalt (III) compounds, and nickel (II) compounds; (B) a ligand selected from the group consisting of certain azopyridines and certain iminopyridines; and (C) methylalumoxane can be used to catalyze the polymerization of diene monomers, such as 1,3-butadiene and isoprene, into polymers, such as high cis-1,4-polybutadiene rubber. Some representative examples of azopyridines that can be utilized in the catalyst systems of this invention include 2-phenylazopyridine, 4-methyl-2-phenylazopyridine, and 2,6-diphenylazopyridine. The subject invention more specifically discloses a process for synthesizing a polybutadiene rubber which comprises polymerizing 1,3-butadiene at a temperature which is within the range of about 10° C. to about 100° C.

Abstract: Provided is a catalyst system for polymerization of monomers having at least one Ziegler-Natta polymerizable bond, comprising: a) a supported Ziegler-Natta transition metal catalyst having a magnesium component modified with a metallocene catalyst component, such that the ratio of magnesium component to metallocene component is within the range of about 1:1 to about 4:1, during its synthesis or production; and b) an effective co-catalyst.

Abstract: A catalyst composition includes: A) a solid catalyst precursor containing a metallocene compound, a magnesium compound and a particulate polymeric material; and B) a cocatalyst containing aluminum compound. The catalyst is prepared by combining metallocene compound, magnesium compound and particles of polymeric material to form a catalyst precursor; and activating the catalyst precursor with alkylaluminums and/or aluminoxanes. Homopolymeric or copolymeric polyolefins are produced by contacting olefins or olefins and alpha-olefins with the catalyst composition.