Manufacturing ethylene interpolymer products at higher production rate

Patent metadata

Field	Value
Publication number	US-11773197-B2
Application number	US-202016866730-A
Country	US
Kind code	B2
Filing date	May 5, 2020
Priority date	Nov 7, 2017
Publication date	Oct 3, 2023
Grant date	Oct 3, 2023

Abstract

This disclosure relates to an improved continuous solution polymerization process wherein production rate is increased. Process solvent, ethylene, optional comonomers, optional hydrogen and a bridged metallocene catalyst formulation are injected into a first reactor to form a first ethylene interpolymer. Optionally, process solvent, ethylene, optional comonomers, optional hydrogen and a bridged metallocene catalyst formulation are injected into a second reactor forming a second ethylene interpolymer. The first and second reactors may be configured in series or parallel modes of operation. Optionally, a third ethylene interpolymer is formed in a third reactor, wherein a homogeneous catalyst formulation or a heterogeneous catalyst formulation is employed. In solution, the first, optional second and optional third ethylene interpolymers are combined, the catalyst is deactivated, the solution is optionally passivated and following a phase separation process an ethylene interpolymer product is recovered.

First claim

We claim:

1. A continuous solution polymerization process comprising two continuously stirred tank reactors in series, wherein the process comprises polymerizing ethylene, and at least one α-olefin, in a process solvent, in one or more of the reactors, and employing at least one bridged metallocene catalyst formulation to form an ethylene interpolymer product comprising a first ethylene interpolymer and a second ethylene interpolymer and 3.7 mol. % to 25 mol. % 1-octene;
wherein the bridged metallocene catalyst formulation comprises:
a component A defined by Formula (I):

wherein:
M is Ti, Hf, or Zf,
G is C, Si, Ge, or Sn,
X is a halogen atom,
R 6 , at each occurrence, is independently selected from H, a C 1-20 hydrocarbyl radical, a C 1-20 alkoxy radical, or a C 6-10 aryl oxide radical, these radicals may be linear, branched or cyclic or further substituted with halogen atoms, C 1-10 alkyl radicals, C 1-10 alkoxy radicals, C 6-10 aryl or aryloxy radicals,
R 1 is H, a C 1-20 hydrocarbyl radical, a C 1-20 alkoxy radical, a C 6-10 aryl oxide radical, or an alkylsilyl radical containing at least one silicon atom and from 3-30 carbon atoms,
R 2 and R 3 are independently selected from H, a C 1-20 hydrocarbyl radical, a C 1-20 alkoxy radical, a C 6-10 aryl oxide radical, or an alkylsilyl radical containing at least one silicon atom and from 3-30 carbon atoms, and
R 4 and R 5 are independently selected from H, a C 1-20 hydrocarbyl radical, a C 1-20 alkoxy radical a C 6-10 aryl oxide radical, or an alkylsilyl radical containing at least one silicon atom and from 3-30 carbon atoms;

a component M, comprising an alumoxane co-catalyst;
a component B, comprising a boron ionic activator; and
wherein the molar ratio of component B to component A is from 0.3:1 to 10:1; and the molar ratio of component M to component A is from 1:1 to 300, and

wherein the process has an increased production rate, PR I , defined by the following formula:
PR I =100×(PR A −PR C )/PR C ≥10%

wherein:
PR A is the production rate of the process, and

PR C is a comparative production rate of a comparative process wherein the bridged metallocene catalyst formulation has been replaced with an unbridged single site catalyst formulation comprising:
cyclopentadienyl tri(tertiary butyl)phosphinimine titanium dichloride, methylaluminoxane,
trityl tetrakis(pentafluoro-phenyl)borate, and
2,6-di-tert-butyl-4-ethylphenol.

2. The process of claim 1 , wherein the bridged metallocene catalyst formulation further comprises a hindered phenol.

3. The process of claim 1 , wherein component M is methylalumoxane (MMAO-7) and component B is trityl tetrakis (pentafluoro-phenyl) borate.

4. The process of claim 1 , further comprising the injection of the bridged metallocene catalyst formulation into the one or more reactors at a catalyst inlet temperature from 20° C. to 70° C.

5. The process of claim 1 , further comprising the injection of the bridged metallocene catalyst formulation into the one or more reactor at a catalyst inlet temperature from 80° C. to 180° C.

6. The process of claim 1 , wherein the process solvent is one or more C 5 to C 12 alkanes.

7. The process of claim 1 , wherein the one or more reactors operate at a temperature from 80° C. to 300° C. and a pressure from 3 MPag to 45 MPag.

8. The process of claim 1 , wherein the process solvent in the one or more reactors has an average reactor residence time from 10 seconds to 720 seconds.

9. The process of claim 1 , wherein the ethylene interpolymer product has:
a dimensionless Long Chain Branching Factor, LCBF, greater than or equal to 0.001;
a residual catalytic metal of from ≥0.03 to ≤5 ppm of hafnium, wherein the residual catalytic metal is measured using neutron activation;
a dimensionless unsaturation ratio, UR, of from ≥−0.40 to ≤0.06, where UR is defined by the following relationship:
UR=(SC U −T U )/T U

wherein, SC U is the amount of a side chain unsaturation per 100 carbons and T U is amount of a terminal unsaturation per 100 carbons, in the ethylene interpolymer product, as determined by ASTM D3124-98 and ASTM D6248-98.

10. The process of claim 1 , wherein the ethylene interpolymer product has a melt index from 0.3 to 500 dg/minute and a density from 0.855 to 0.975 g/cc; wherein the melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.) and density is measured according to ASTM D792.

11. The process of claim 1 , wherein the ethylene interpolymer product further comprises a third ethylene interpolymer.

12. The process of claim 1 , wherein the ethylene interpolymer product has a polydispersity, M w /M n , from 1.7 to 25 and a CDBI 50 from 1% to 98%, wherein CDBI 50 is measured using CTREF; wherein the weight average molecular weight, M w , and the number average molecular weight, M n , are measured using conventional size exclusion chromatography and CDBI 50 is measured using CTREF.

Assignees

• Nova Chem Int Sa

Inventors

• Kazemi Niousha
• Kleczek Monika
• Konaganti Vinod
• Gillon Bronwyn
• Goyal Shivendra
• Sibtain Fazle
• Kasiri Sepideh
• Salomons Stephen
• Taylor Kenneth
• Keshtkar Mehdi

Classifications

• C08F210/16 Primary

  Copolymers of ethene with alpha-alkenes, e.g. EP rubbers · CPC title

• C08J5/18 Primary

  Manufacture of films or sheets · CPC title

• B32B27/08

  of synthetic resin · CPC title

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• C08F4/65908

  in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+ · CPC title