Abstract: Polymerization processes for producing ethylene-based plastomers and elastomers having densities less than 0.91 g/cm3 utilize a metallocene-based catalyst system containing a chemically-treated solid oxide. These polymerization processes can be conducted in a slurry reactor, a solution reactor, and/or a gas phase reactor. Ethylene polymers produced from the polymerization process can be characterized by a density of less than 0.91 g/cm3, a CY-a parameter of less than 0.2, and a ratio of HLMI/MI of at least 30, or a density less than 0.91 g/cm3, a CY-a parameter from 0.25 to 0.75, and a ratio of Mw/Mn from 2 to 3.

Abstract: The invention provides a polymerization process comprising polymerizing a reaction mixture comprising one or more monomer types, at least one catalyst, and at least one solvent, to form a polymer dispersion, and wherein the at least one catalyst is soluble in the at least one solvent, and wherein the polymer forms a dispersed phase in the solvent, and wherein the at least one solvent is a hydrocarbon. The invention provides a composition comprising an ethylene-based polymer comprising at least the following properties: a) a weight average molecular weight (Mw(abs)) greater than, or equal to, 60,000 g/mole; and b) a molecular weight distribution (Mw(abs)/Mn(abs)) greater than, or equal to, 2.3.

Abstract: The invention is directed to a metallocene catalyst system and a process for preparing the system. The metallocene catalyst system comprises a support and metallocene bound substantially throughout the support. The selection of certain supports facilitates the production of metallocene catalyst systems having increased catalytic activity than previously recognized.

Abstract: Disclosed herein is an in-reactor produced multi-component copolymer comprises a semi-crystalline component having a crystallinity of 20% or more, and an amorphous component having a crystallinity of 5% or less. The copolymer comprises at least 80 wt % of units derived from propylene and from about 1 to about 20 wt % of units derived from at least one C6 to C12 alpha-olefin. The copolymer has a viscosity at 190° C. of at least 530 mPa sec and a heat of fusion between about 10 and about 70 J/g. An adhesive containing the copolymer exhibits a good balance of adhesive properties and mechanical strength.

Abstract: The invention is directed to a metallocene catalyst system comprising an inert silica support having pores with a peak pore volume of greater than about 0.115 mL/g at a pore diameter between about 250 Angstroms and about 350 Angstroms, and an alumoxane activator, with the metallocene being bound substantially throughout the support. The activator is grafted to the support in a solvent at a reflux temperature of toluene to obtain an aluminoxane on silica, and a metallocene component is added to make a MCS having a metallocene loading of about 2 wt %. This facilitates the production of metallocene catalyst systems having increased catalytic activity than previously recognized that is at least about 20 percent higher than the catalytic activity for a metallocene loading of about 1 wt % where the activator is grafted to the support at room temperature.

Abstract: Methods of forming supported catalyst systems, supported catalyst systems and polymerization processes utilizing the supported catalyst systems are described herein. The methods generally include providing an inorganic support material and contacting the inorganic support material with a support solvent to form a support solution. The methods further include contacting the support solution with a fluorine containing compound represented by the formula AlFpX3-pBq to impregnate the fluorine containing compound within the inorganic support material and form an intermediate, wherein X is selected from Cl, Br and OH?, B is H2O, p is selected from 1 to 3 and q is selected from 0 to 6. In addition, the methods include drying the intermediate to remove the solvent therefrom and heating the intermediate at a temperature of at least about 300° C.

Abstract: Supported catalyst systems and methods of forming the same are described herein. In one specific embodiment, the methods generally include providing an inorganic support material and contacting the inorganic support material with an aluminum fluoride compound represented by the formula AlFpX3-pBq to form an aluminum fluoride impregnated support, wherein X is selected from Cl, Br and OH?, B is H2O, p is selected from 1 to 3 and q is selected from 0 to 6. The method further includes contacting the aluminum fluoride impregnated support with a transition metal compound to form a supported catalyst system, wherein the transition metal compound is represented by the formula [L]mM[A]n; wherein L is a bulky ligand, A is a leaving group, M is a transition metal and m and n are such that a total ligand valency corresponds to the transition metal valency.

Abstract: Film formed from a polyethylene resin composition which obeys a dynamic rheological relationship at 190° C. between melt storage modulus G?, measured in Pa and at a dynamic frequency where the loss modulus G?=3000 Pa, and dynamic complex viscosity ?*100, measured in Pa·s at 100 rad/s, such that (a) G?(G?=3000)>?0.86?*100+z where z=3800, and at the same time (b) G?(G?=3000)>0.875?*100?y where y=650, and having an impact strength (DDT) of at least 250 g, measured on 15 ?m thick film (blown under conditions with BUR=5:1 and Neck Height=8×D) conditioned for 48 hours at 20°-25° C., according to ASTM D1709.

Abstract: Catalyst for the polymerization and/or copolymerization of olefins which is obtainable by application to a finely divided inorganic support and concluding calcination at temperatures of from 350 to 1050° C. and has a chromium content of from 0.1 to 5% by weight and a zirconium content of from 0.5 to 10% by weight, in each case based on the element in the finished catalyst, with the molar ratio of zirconium to chromium being from 0.6 to 5.

Abstract: Process for preparing a supported catalyst for the polymerization and/or copolymerization of olefins which has a chromium content of from 0.01 to 5% by weight, based on the element, which comprises (a) preparing a homogeneous solution comprising an organic or inorganic chromium compound and at least one further organic or inorganic compound of elements selected from among Mg, Ca, Sr, B, Al, Si, P, Bi, Sc, V, Mn, Fe, Co, Ni, Cu, Zn, Zr, Nb, Mo, Ru, Rh, Pd, Hf, Ta, W in a protic or aprotic polar solvent, (b) bringing the solution from a) into contact with a finely divided inorganic support to form a catalyst precursor, (c) if appropriate, removing the solvent from the catalyst precursor and (d) calcining the catalyst precursor at temperatures of from 350 to 950° C., preferably 400 to 900° C., under oxidative conditions.

Abstract: The present invention is directed to a high melt flow rate high crystallinity polypropylene homopolymer. The present invention likewise describes a bulk polymerization process using a Ziegler-Natta catalyst to produce the high melt flow rate high crystallinity polypropylene homopolymer according to the invention.

Abstract: Catalyst components, methods of forming catalyst compositions, polymerization processes utilizing the catalyst compositions and polymers formed thereby are described herein. The methods generally include providing a magnesium dialkoxide compound, contacting the magnesium dialkoxide compound with a first agent to form a solution of a reaction product “A1”, contacting the solution of reaction product “A1” with a reducing agent to form a reduced reaction product “A2”, contacting reduced reaction product “A2” with a second agent to form a solid reaction product “A3”, contacting solid reaction product “A3” with a metal halide to form reaction product “B” and contacting reaction product “B” with an organoaluminum compound to form a catalyst component.

Abstract: A shrink film comprising a polyethylene film, characterized in that said polyethylene is an ethylene copolymer mixture having a molecular weight distribution in the range 10 to 35, a density of 915 to 940 kg/m3, a weight average molecular weight of at least 100000 D and an MFR2.16 (190° C.) of 0.1 to 0.9 kg/m3, which copolymer mixture is produced by a two or more stage copolymerization of ethylene and 2 to 10% mole (relative to ethylene) of a C3-12 alpha-olefin comonomer in a series of reactors including at least one slurry loop reactor and at least one gas phase reactor using a heterogeneous Ziegler-Natta catalyst.

Abstract: High melt flow rate high crystallinity polypropylene homopolymer are produced in a bulk polymerization process using a Ziegler-Natta catalyst containing a combination of two internal electron donors and selected external donors. The high melt flow rate, high crystallinity polypropylene homopolymers produced according to the current invention display improved flexural modulus and tensile yield stress when nucleated.

Abstract: A process for the preparation of a silicon containing transition metal compound that includes the steps of (a) non-hydrolytic sol-gel condensation of a silane of formula LxSiQn wherein L is a ?-bonded ligand, Q is an anionic ligand, and x+n=4 with a halogenated silane (or siloxane) and an alkoxysilane, (b) optionally alkylation, (c) deprotonation and (d) addition of a transition metal compound. The process allows for the preparation of transition metal compounds which may suitably be used with cocatalysts for the polymerization of olefins, in particular for such processes carried out in the gas phase.

Abstract: The present invention discloses a polyethylene catalyst and a process for preparing the same, said catalyst being composed of a main component of catalyst and a cocatalyst, wherein the main component of catalyst is prepared by reacting: (1) a magnesium-alcohol complex, (2) an alkyl aluminum compound having a formula R3nAlCl3-n supported on silica, and (3) a titanium compound having a formula Ti(OR2)mCl4-m, and the cocatalyst is an organic aluminum compound. The catalyst of the present invention has advantages including high polymerization activity, less difference between the polymerization activities at low hydrogen level condition and at high hydrogen level condition, stable polymerization reaction, good particle morphology of catalyst, and less fine powder of polymer product.

Abstract: This invention relates to a method to polymerize olefins comprising contacting a solid aluminum or solid titanium compound with a supported catalyst compound, heating the solid aluminum or solid titanium compound to cause the solid compound to vaporize, optionally activating the support by oxidation, thereafter contacting the activated support with one or more olefin monomers.

Abstract: The invention relates to highly flowable propylene block copolymers that comprise 50 to 80 wt.-% of a propylene homopolymer and 10 to 70 wt.-% of a propylene copolymer having 5 to 50 wt.-% of a C2–C8 alk-1-ene polymerized into it that is different from propylene, and that are obtainable from the gaseous phase by a two-step polymerization by means of a Ziegler-Natta catalyst system. In a first polymerization step, the propylene is polymerized at a pressure of 10 to 50 bar, a temperature of 50 to 100° C. and an average dwelling time of the reaction mixture of 0.3 to 5 hours in the presence of at least 2.0% by volume, based on the total volume, of hydrogen. The propylene homopolymer obtained in said first polymerization step is transferred together with the Ziegler-Natta catalyst system into an intermediate container, expanded for 0.01 to 5 minutes to less than 5 bar and maintained at a temperature of 10 to 80° C.

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: The invention concerns a cationic catalyst system comprising an initiator (I), a catalyst (K) and a cocatalyst (CoK). The cocatalyst (CoK) is an agent releasing the active polymerizing center of its counter anion generated by the reaction between the catalyst (K) and the initiator (I). Said cocatalyst is characterized by the existence of a double bond electron-depleted by an electroattractive group. It is selected, for example, from the group consisting of the following complexing agents including o-chloranyl (3,4,5,6-tetrachloro-1,2-benzoquinone), p-chloranyl (2,3,5,6-tetrachloro-1,4-benzoquinone), nitrobenzene, trinitrobenzene, or tetracyanoethylene.

Abstract: The present invention provides a new copolymer of propylene and a conjugated diene having a carbon-carbon double bond in a side chain, wherein a molar ratio of a total of 1,2-adducts and 3,4-adducts to 1,4-adducts, derived from the conjugated diene, is 100:0. The copolymer is prepared in a process, characterized in that propylene and the conjugated diene are copolymerized in the presence of hydrogen, an organometallic compound comprising a transition metal selected from the group 4 of the periodic table, and at least one Lewis acid.

Abstract: A method of preparing ultra high melt flow polypropylene having reduced xylene solubles is provided. The method utilizes a diether internal donor-containing Ziegler-Natta catalyst system to polymerize propylene. The polypropylene produced is characterized by having a melt flow of at least about 300 g/10 min and a xylene solubles of not more than about 3.5% and no peroxide residue. The catalyst system may also include an internal phthalate donor. The method of the invention allows the amount of external donors to be reduced, or even eliminated, without significant increases in xylene solubles.

Abstract: A novel loop/slurry olefin polymerization process is provided which produces ultra-high molecular weight ethylene homopolymer.

Abstract: A clay-filled polyolefin composition and process for making it are disclosed. The process involves treatment of a non-acid-treated smectite clay with a Ziegler-Natta catalyst in the presence of a hydrocarbon and subsequent polymerization of an olefin in the presence of the treated clay and an organoaluminum cocatalyst. Results indicate that filled compositions produced by this process contain exfoliated clay.

Abstract: The application discloses supported initiators for transition metal mediated living free radical and/or atom transfer polymerisation comprising an initiator moiety attached to a support via a selectively cleavable link, and their use to produce polymers.

Abstract: A new synthesis of a Ziegler-Natta catalyst uses a multi-step preparation that includes treating a magnesium dialkoxide compound with halogenating/titanating agents, 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: Ethylene and optional comonomers are polymerized using a supported metallocene catalyst, an alumoxane activator, and triisobutylaluminum (TIBAL). A silica support is first pretreated with a silane compound and then with an organoboron compound. The treated silica is then combined with a Group 4 metallocene complex and an alumoxane to generate a supported, activated catalyst. While it was previously thought that the particular support treatment technique used herein provided benefits only for polymerizations catalyzed by non-metallocene single-site complexes, it has now been found that similar benefits can be realized even with conventional metallocenes if TIBAL is selected as the scavenger.

Abstract: The present invention provides a novel process for the preparation of isoolefin copolymers in the presence of zirconium halides or hafnium halides or mixtures thereof and organic nitro compounds, especially for the preparation of butyl rubbers, as well as isoolefin copolymers composed of isobutene, isoprene and, optionally, further monomers.

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 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: 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: The invention is directed to a process for the preparation of a catalyst component for the polymerization of an olefin by: a) contacting metallic magnesium with an organic halide RX, where R is an organic group containing up to 20 carbon atoms and X is a halide, whereupon the dissolved reaction product I is separated from the solid residual products and whereafter, b) an alkoxy group or aryloxy group containing silane compound is added to the obtained reaction product I, whereupon the precipitate formed is purified to obtain reaction product II, c) which reaction product II is subsequently contacted with TiCl4 and the resulting product is purified to obtain the catalyst component. The invention is characterized in that in step b) the silane compound and reaction product I are introduced simultaneously to a mixing device.

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: 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: A novel loop/slurry olefin polymerization process is provided which produces ultra high molecular weight ethylene homopolymers and ultra high molecular weight ethylene copolymers. Catalyst systems used are selected from the group consisting of inorganic oxide supported titanium-containing catalyst systems, inorganic oxide supported organo-zirconium catalyst systems and inorganic oxide supported organo-hafnium catalyst systems.

Abstract: A method of preparing ultra high melt flow polypropylene having reduced xylene solubles is provided. The method utilizes a diether internal donor-containing Ziegler-Natta catalyst system to polymerize propylene. The polypropylene produced is characterized by having a melt flow of at least about 300 g/10 min and a xylene solubles of not more than about 3.5% and no peroxide residue. The catalyst system may also include an internal phthalate donor. The method of the invention allows the amount of external donors to be reduced, or even eliminated, without significant increases in xylene solubles.

Abstract: The present invention includes a bimodal polyethylene polymerization process wherein metallocene catalyst to is used to adjust the hydrogen response of a Ziegler-Natta catalyst. The polymerization may be carried out in a single reactor or in two or more reactors in series, preferably two or more continuously stirred tank reactors in series. In an embodiment having two or more reactors, the Zeigler-Natta catalyst is added to a first reactor and the metallocene catalyst is added to a downstream reactor. In another embodiment having two or more reactors, the Zeigler-Natta catalyst and metallocene catalyst are added to the same reactor, preferably an upstream reactor. A preferred Zeigler-Natta catalyst comprises TiCl4, and a preferred metallocene catalyst comprises bis(cyclopentadienyl) titanium dichloride.

Abstract: Catalyst system for the polymerization of olefins CH2═CHR, wherein R is hydrogen or a hydrocarbon radical having 1-12 carbon atoms, comprising the product of the reaction between (a) a solid catalyst component comprising Mg, Ti, and halogen, (b) dimethylaluminium chloride (DMAC) and (c) an alkylaluinium compound, in which the molar ratio between (b) and (c) is lower than 10. This kind of catalyst system is particularly suitable for the preparation of copolymers of ethylene with &agr;-olefins due to its high capacity for incorporating the comonomer while at the same time maintaining high yields.

Abstract: Spherical catalyst components for the polymerization of olefins of formula RCH═CHR, in which R is, independently, hydrogen or a hydrocarbon group with 1-10 carbon atoms, containing a homogeneous transition metal compound of formula MPx, in which M is a transition metal M of Groups 3 to 11 or the lanthanide or actinide Groups of the Periodic Table of the Elements (new IUPAC version); P is a ligand that is coordinated to the metal M and x is the valence of the metal M. The transition metal compound is dispersed in a solid hydrocarbon matrix having a melting point above 70° C.

Abstract: The present invention relates to a process for the preparation of random copolymers of propylene with c2-c10 &agr;-olefins, carried out in the presence of a catalyst comprising: A) A solid component comprising a titanium compound supported on mgcl2 in active form and an electron-donor compound; b) An alkyl-al compound, and c) An electron-donor compound selected from the group of 1,3-diethers. The copolymers obtained using the said process show, for an equivalent content of &agr;-olefin, a lower content of xylene-soluble fractions when compared with the copolymers obtained with the catalysts of the prior art.

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: The present invention includes a bimodal polyethylene polymerization process wherein metallocene catalyst to is used to adjust the hydrogen response of a Ziegler-Natta catalyst. The polymerization may be carried out in a single reactor or in two or more reactors in series, preferably two or more continuously stirred tank reactors in series. In an embodiment having two or more reactors, the Zeigler-Natta catalyst is added to a first reactor and the metallocene catalyst is added to a downstream reactor. In another embodiment having two or more reactors, the Zeigler-Natta catalyst and metallocene catalyst are added to the same reactor, preferably an upstream reactor. A preferred Zeigler-Natta catalyst comprises TiCl4, and a preferred metallocene catalyst comprises bis(cyclopentadienyl) titanium dichloride.

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: The present invention provides a novel process for the preparation of isoolefin copolymers in the presence of zirconium halides and/or hafnium halides and organic acid halides, in particular for the preparation of butyl rubbers, as well as isoolefin copolymers constructed of isobutene, isoprene and optionally further monomers.

Abstract: A novel continuous gas phase polymerization process for producing polyethylene and interpolymers of ethylene and at least one other olefin is provided wherein a non-aromatic halogenated hydrocarbon is used in a specified amount such that the activity of the titanium, zirconium and/or hafnium containing Ziegler-Natta catalyst is increased.

Abstract: A novel loop/slurry olefin polymerization process is provided which produces ultra high molecular weight ethylene homopolymers and ultra high molecular weight ethylene copolymers. Catalyst systems used are selected from the group consisting of inorganic oxide supported titanium-containing catalyst systems, inorganic oxide supported organo-zirconium catalyst systems and inorganic oxide supported organo-hafnium catalyst systems.

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: A method of preparing ultra high melt flow polypropylene having reduced xylene solubles is provided. The method utilizes a diether internal donor-containing Ziegler-Natta catalyst system to polymerize propylene. The polypropylene produced is characterized by having a melt flow of at least about 300 g/10 min and a xylene solubles of not more than about 3.5% and no peroxide residue. The catalyst system may also include an internal phthalate donor. The method of the invention allows the amount of external donors to be reduced, or even eliminated, without significant increases in xylene solubles.