[미국특허]
Use of hydrogen scavenging catalysts to control polymer molecular weight and hydrogen levels in a polymerization reactor
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C08F-004/642
C08F-004/643
C08F-004/6592
B01J-031/22
출원번호
US-0488578
(2012-06-05)
등록번호
US-8501654
(2013-08-06)
발명자
/ 주소
Murray, Rex E.
Beaulieu, William B.
Yang, Qing
Ding, Errun
Glass, Gary L.
Solenberger, Alan L.
Secora, Steven J.
출원인 / 주소
Chevron Philips Chemical Company LP
대리인 / 주소
Merchant & Gould P.C.
인용정보
피인용 횟수 :
4인용 특허 :
90
초록▼
The present invention provides dual catalyst systems containing a metallocene catalyst and a hydrogen scavenging catalyst, and polymerization processes employing these dual catalyst systems. Due to a reduction in hydrogen levels in the polymerization processes, olefin polymers produced from these po
The present invention provides dual catalyst systems containing a metallocene catalyst and a hydrogen scavenging catalyst, and polymerization processes employing these dual catalyst systems. Due to a reduction in hydrogen levels in the polymerization processes, olefin polymers produced from these polymerization processes may have a higher molecular weight, a lower melt index, and higher levels of unsaturation.
대표청구항▼
1. A catalyst composition comprising: catalyst component I comprising a metallocene compound;catalyst component II comprising a hydrogen scavenging catalyst;an organoaluminum compound; andan activator-support comprising a solid oxide treated with an electron-withdrawing anion; wherein a molar ratio
1. A catalyst composition comprising: catalyst component I comprising a metallocene compound;catalyst component II comprising a hydrogen scavenging catalyst;an organoaluminum compound; andan activator-support comprising a solid oxide treated with an electron-withdrawing anion; wherein a molar ratio of catalyst component I to catalyst component II is in a range from about 40:1 to about 10,000:1. 2. The catalyst composition of claim 1, wherein the molar ratio of catalyst component I to catalyst component II is in a range from about 50:1 to about 1000:1. 3. The catalyst composition of claim 1, wherein: the organoaluminum compound comprises trimethylaluminum, triethylaluminum, tri-n-propylaluminum, tri-n-butylaluminum, triisobutylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum, diisobutylaluminum hydride, diethylaluminum ethoxide, diethylaluminum chloride, or any combination thereof; andthe activator-support comprises fluorided alumina, chlorided alumina, bromided alumina, sulfated alumina, fluorided silica-alumina, chlorided silica-alumina, bromided silica-alumina, sulfated silica-alumina, fluorided silica-zirconia, chlorided silica-zirconia, bromided silica-zirconia, sulfated silica-zirconia, fluorided silica-titania, fluorided silica-coated alumina, sulfated silica-coated alumina, phosphated silica-coated alumina, or any combination thereof. 4. The catalyst composition of claim 1, wherein the hydrogen scavenging catalyst comprises Ru, Rh, Pt, Pd, Fe, Ni, Nb, Ti, or a combination thereof. 5. The catalyst composition of claim 1, wherein catalyst component II comprises: a compound having the formula or any combination thereof, wherein: M5 is Zr or Hf;X8 and X9 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;Cp2 and Cp3 are independently a cyclopentadienyl or indenyl, any substituent on Cp2 and Cp3 is independently H or a hydrocarbyl group having up to 18 carbon atoms; andE5 is a bridging group having the formula —(CH2)n—, wherein n is an integer from 2 to 8, inclusive. 6. The catalyst composition of claim 5, wherein catalyst component I comprises: a compound having formula (C);a compound having formula (D); orany combination thereof, wherein: formula (C) is wherein: M3 is Zr or Hf;X4 and X5 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;E3 is a bridging group selected from: a cyclic or heterocyclic bridging group having up to 18 carbon atoms,a bridging group having the formula >E3AR7AR8A, wherein E3A is C or Si, and R7A and R8A are independently H or a hydrocarbyl group having up to 18 carbon atoms,a bridging group having the formula —CR7BR8B—CR7CR8C—, wherein R7B, R8B, R7C, and R8C are independently H or a hydrocarbyl group having up to 10 carbon atoms, ora bridging group having the formula —SiR7DR8D—SiR7ER8E—, wherein R7D, R8D, R7E, and R8E are independently H or a hydrocarbyl group having up to 10 carbon atoms;R9 and R10 are independently H or a hydrocarbyl group having up to 18 carbon atoms; andCp1 is a cyclopentadienyl or indenyl group, any substituent on Cp1 is H or a hydrocarbyl or hydrocarbylsilyl group having up to 18 carbon atoms; and formula (D) is wherein: M4 is Zr or Hf;X6 and X7 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;E4 is a bridging group selected from: a cyclic or heterocyclic bridging group having up to 18 carbon atoms,a bridging group having the formula >E4AR12AR13A, wherein E4A is C or Si, and R12A and R13A are independently H or a hydrocarbyl group having up to 18 carbon atoms,a bridging group having the formula —CR12BR13B—CR12CR13C—, wherein R12B, R13B, R12C, and R13C are independently H or a hydrocarbyl group having up to 10 carbon atoms, ora bridging group having the formula —SiR12DR13D—SiR12ER13E—, wherein R12D, R13D, R12E, and R13E are independently H or a hydrocarbyl group having up to 10 carbon atoms; andR14, R15, R16, and R17 are independently H or a hydrocarbyl group having up to 18 carbon atoms. 7. The catalyst composition of claim 1, wherein catalyst component II comprises: or any combination thereof. 8. The catalyst composition of claim 1, wherein catalyst component II comprises: or a combination thereof. 9. A catalyst composition comprising: catalyst component I comprising a metallocene compound;catalyst component II comprising a hydrogen scavenging catalyst; andan activator comprising an aluminoxane compound, an organoboron or organoborate compound, an ionizing ionic compound, or any combination thereof;wherein a molar ratio of catalyst component I to catalyst component II is in a range from about 40:1 to about 10,000:1. 10. An olefin polymerization process comprising contacting the catalyst composition of claim 9 with an olefin monomer and optionally an olefin comonomer under polymerization conditions to produce an olefin polymer. 11. The process of claim 9, wherein the process is conducted in a batch reactor, slurry reactor, gas-phase reactor, solution reactor, high pressure reactor, tubular reactor, autoclave reactor, or a combination thereof. 12. The process of claim 9, wherein catalyst component II comprises: a compound having the formula or any combination thereof, wherein: M5 is Zr or Hf;X8 and X9 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;Cp2 and Cp3 are independently a cyclopentadienyl or indenyl, any substituent on Cp2 and Cp3 is independently H or a hydrocarbyl group having up to 18 carbon atoms; andE5 is a bridging group having the formula —(CH2)n—, wherein n is an integer from 2 to 8, inclusive. 13. The process of claim 9, wherein the olefin monomer is ethylene, and the olefin comonomer comprises propylene, 1-butene, 2-butene, 3-methyl-1-butene, isobutylene, 1-pentene, 2-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 2-hexene, 3-ethyl-1-hexene, 1-heptene, 2-heptene, 3-heptene, 1-octene, 1-decene, styrene, or a mixture thereof. 14. The process of claim 13, wherein: the molar ratio of catalyst component I to catalyst component II is in a range from about 50:1 to about 1000:1; andthe hydrogen scavenging catalyst has a hydrogen removal activity greater than about 5,000 moles of hydrogen (H2) per mole of the hydrogen scavenging catalyst per hour. 15. The process of claim 13, wherein: a weight-average molecular weight (Mw) of the olefin polymer produced by the process is from about 10% to about 500% greater than a weight-average molecular weight (Mw) of an olefin polymer obtained under the same polymerization conditions without catalyst component II; ora melt index (MI) of the olefin polymer produced by the process is from about 15% to about 95% less than a MI of an olefin polymer obtained under the same polymerization conditions without catalyst component II; ora high load melt index (HLMI) of the olefin polymer produced by the process is from about 15% to about 95% less than a HLMI of an olefin polymer obtained under the same polymerization conditions without catalyst component II; orany combination thereof. 16. The process of claim 13, wherein: a melt index of the olefin polymer produced by the process is in a range from about 0.1 to about 5 g/10 min; ora density of the olefin polymer produced by the process is in a range from about 0.89 to about 0.96 g/cm3; oran average total polymer unsaturation per chain of the olefin polymer produced by the process is in a range from about 1.01 to about 50; orany combination thereof. 17. The process of claim 13, wherein catalyst component II comprises: or any combination thereof. 18. A method of reducing an amount of hydrogen present in an olefin polymerization reactor system, the method comprising: introducing a hydrogen scavenging catalyst having a hydrogen removal activity of greater than about 5,000 moles of hydrogen (H2) per mole of the hydrogen scavenging catalyst per hour to the polymerization reactor system. 19. The method of claim 18, wherein the method is configured for transitioning from a Ziegler-Natta catalyst system to a metallocene catalyst system in the polymerization reactor system. 20. The method of claim 18, wherein the method is configured for transitioning from a chromium catalyst system to a metallocene catalyst system in the polymerization reactor system. 21. The method of claim 18, wherein the hydrogen scavenging catalyst has a hydrogen removal activity greater than about 25,000 moles of hydrogen (H2) per mole of the hydrogen scavenging catalyst per hour. 22. The method of claim 18, wherein the hydrogen scavenging catalyst comprises: a compound having the formula or any combination thereof, wherein: M5 is Zr or Hf;X8 and X9 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;Cp2 and Cp3 are independently a cyclopentadienyl or indenyl, any substituent on Cp2 and Cp3 is independently H or a hydrocarbyl group having up to 18 carbon atoms; andE5 is a bridging group having the formula —(CH2)n—, wherein n is an integer from 2 to 8, inclusive. 23. The method of claim 18, wherein the hydrogen scavenging catalyst comprises: or any combination thereof. 24. The method of claim 18, wherein the polymerization reactor system comprises a slurry reactor, gas-phase reactor, solution reactor, high pressure reactor, tubular reactor, autoclave reactor, or a combination thereof. 25. The method of claim 24, wherein an ethylene homopolymer, ethylene/1-butene copolymer, ethylene/1-hexene copolymer, ethylene/1-octene copolymer, or a combination thereof, is produced in the polymerization reactor system. 26. The catalyst composition of claim 9, wherein: the molar ratio of catalyst component I to catalyst component II is in a range from about 50:1 to about 1000:1; andthe activator comprises an aluminoxane compound. 27. The catalyst composition of claim 9, wherein the hydrogen scavenging catalyst comprises Ru, Rh, Pt, Pd, Fe, Ni, Nb, Ti, or a combination thereof. 28. The catalyst composition of claim 9, wherein catalyst component II comprises: a compound having the formula or any combination thereof, wherein: M5 is Zr or Hf;X8 and X9 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;Cp2 and Cp3 are independently a cyclopentadienyl or indenyl, any substituent on Cp2 and Cp3 is independently H or a hydrocarbyl group having up to 18 carbon atoms; andE5 is a bridging group having the formula —(CH2)n—, wherein n is an integer from 2 to 8, inclusive. 29. The catalyst composition of claim 9, wherein catalyst component I comprises: a compound having formula (C);a compound having formula (D); orany combination thereof, wherein: formula (C) is wherein: M3 is Zr or Hf;X4 and X5 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;E3 is a bridging group selected from: a cyclic or heterocyclic bridging group having up to 18 carbon atoms,a bridging group having the formula >E3AR7AR8A, wherein E3A is C or Si, and R7A and R8A are independently H or a hydrocarbyl group having up to 18 carbon atoms,a bridging group having the formula —CR7BR8B—CR7CR8C—, wherein R7B, R8B, R7C, and R8C are independently H or a hydrocarbyl group having up to 10 carbon atoms, ora bridging group having the formula —SiR7DR8D—SiR7ER8E—, wherein R7D, R8D, R7E, and R8E are independently H or a hydrocarbyl group having up to 10 carbon atoms;R9 and R10 are independently H or a hydrocarbyl group having up to 18 carbon atoms; andCp1 is a cyclopentadienyl or indenyl group, any substituent on Cp1 is H or a hydrocarbyl or hydrocarbylsilyl group having up to 18 carbon atoms; and formula (D) is wherein: M4 is Zr or Hf;X6 and X7 are independently F; Cl; Br; I; methyl; benzyl; phenyl; H; BH4; OBR2 or SO3R, wherein R is an alkyl or aryl group having up to 18 carbon atoms; or a hydrocarbyloxide group, a hydrocarbylamino group, or a hydrocarbylsilyl group, any of which having up to 18 carbon atoms;E4 is a bridging group selected from: a cyclic or heterocyclic bridging group having up to 18 carbon atoms,a bridging group having the formula >E4AR12AR13A, wherein E4A is C or Si, and R12A and R13A are independently H or a hydrocarbyl group having up to 18 carbon atoms,a bridging group having the formula —CR12BR13B—CR12CR13C—, wherein R12B, R13B, R12C, and R13C are independently H or a hydrocarbyl group having up to 10 carbon atoms, ora bridging group having the formula —SiR12DR13D—SiR12ER13E—, wherein R12D, R13Dl , R12E, and R13E are independently H or a hydrocarbyl group having up to 10 carbon atoms; andR14, R15, R16, and R17 are independently H or a hydrocarbyl group having up to 18 carbon atoms. 30. The catalyst composition of claim 9, wherein catalyst component II comprises: or any combination thereof 31. The process of claim 10, wherein the catalyst composition is contacted with ethylene and an olefin comonomer comprising 1-butene, 1-hexene, 1-octene, or a mixture thereof. 32. The process of claim 31, wherein: the molar ratio of catalyst component I to catalyst component II is in a range from about 50:1 to about 1000:1; andthe activator comprises an aluminoxane compound.
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