Catalyst compositions comprising support materials having an improved particle-size distribution

Abstract

A catalyst composition that includes a support material having an improved particle-size distribution is provided. Processes for producing polyolefin composition also are provided. Polymers and films also are provided. An example of a catalyst composition is a supported multi-transition-metal catalyst composition that includes: (a) at least two catalyst components selected from the group consisting of: a nonmetallocene catalyst component and a metallocene catalyst component; (b) a support material that has a D 50 of less than about 30 microns and a particle size distribution having a D 90 /D 10 ratio of less than about 6; and (c) an activator.

1 . A process for producing a polyolefin composition comprising: contacting hydrogen and ethylene monomers with a supported multi-transition-metal catalyst composition to form a polyolefin composition; wherein the supported multi-transition-metal catalyst composition comprises: 
 (a) at least two catalyst components selected from the group consisting of: a nonmetallocene catalyst component and a metallocene catalyst component;    (b) a support material that has a D 50  of less than about 30 microns and a particle size distribution having a D 90 /D 10  ratio of less than about 6; and    (c) an activator.    
   
   
       2 . The process of  claim 1 , wherein the nonmetallocene catalyst component is a Ziegler-Natta catalyst component that comprises a nonmetallocene transition metal compound selected from the group consisting of Group 4 and Group 5 halides, oxides, oxyhalides, alkoxides, and mixtures thereof.  
   
   
       3 . The process of  claim 1 , wherein the support material comprises silica.  
   
   
       4 . The process of  claim 1 , wherein the support material has a D 90  of less than about 50 microns.  
   
   
       5 . The process of  claim 1 , wherein the metallocene catalyst component is represented by the formulae:  
       Cp A Cp B MX n  and Cp A (A)Cp B MX n    
     wherein each Cp A  and Cp B  are the same or different and are substituted or unsubstituted cyclopentadienyl rings or ligands isolobal to cyclopentadienyl, each bound to M; M is a Group 4, 5, or 6 atom; X is selected from the group consisting of C 1  to C 6  alkyls, C 6  aryls, C 7  to C 12  alkylaryls, fluorinated C 1  to C 6  alkyls, fluorinated C 6  aryls, fluorinated C 7  to C 12  alkylaryls, chlorine and fluorine; n is 1 or 2; and (A) is a divalent bridging group; characterized in that at least one X is a fluorine or fluorinated hydrocarbonyl.  
   
   
       6 . A supported multi-transition-metal catalyst composition comprising: 
 (a) at least two catalyst components selected from the group consisting of: a nonmetallocene catalyst component and a metallocene catalyst component;    (b) a support material that has a D 50  of less than about 30 microns and a particle size distribution having a D 90 /D 10  ratio of less than about 6; and    (c) an activator.    
   
   
       7 . The supported multitransition metal catalyst composition of  claim 6 , wherein the metallocene catalyst component is represented by the formulae:  
       Cp A Cp B MX n  and Cp A (A)Cp B MX n    
     wherein each Cp A  and Cp B  are the same or different and are substituted or unsubstituted cyclopentadienyl rings or ligands isolobal to cyclopentadienyl, each bound to M; M is a Group 4, 5, or 6 atom; X is selected from the group consisting of C 1  to C 6  alkyls, C 6  aryls, C 7  to C 12  alkylaryls, fluorinated C 1  to C 6  alkyls, fluorinated C 6  aryls, fluorinated C 7  to C 12  alkylaryls, chlorine and fluorine; n is 1 or 2; and (A) is a divalent bridging group; characterized in that at least one X is a fluorine or fluorinated hydrocarbonyl.  
   
   
       8 . The supported multitransition metal catalyst composition of  claim 6 , wherein the nonmetallocene catalyst component is a Ziegler-Natta catalyst component that comprises a nonmetallocene transition metal compound selected from the group consisting of Group 4 and Group 5 halides, oxides, oxyhalides, alkoxides, and mixtures thereof.  
   
   
       9 . The supported multitransition metal catalyst composition of  claim 6 , wherein the support material comprises silica.  
   
   
       10 . The supported multitransition metal catalyst composition of  claim 6 , wherein the support material has a D 90  of less than about 50 microns.  
   
   
       11 . A polymer made from a process comprising: 
 contacting hydrogen and ethylene monomers with a supported multi-transition-metal catalyst composition to form a polyolefin composition;    wherein the supported multi-transition-metal catalyst composition comprises: 
 (1) at least two catalyst components selected from the group consisting of: a nonmetallocene catalyst component and a metallocene catalyst component;  
 (2) a support material that has a D 50  of less than about 30 microns and a particle size distribution having a D 90 /D 10  ratio of less than about 6; and  
 (3) an activator.  
   
   
   
       12 . The polymer of  claim 11 , wherein the nonmetallocene catalyst component is a Ziegler-Natta catalyst component that comprises a nonmetallocene transition metal compound selected from the group consisting of Group 4 and Group 5 halides, oxides, oxyhalides, alkoxides, and mixtures thereof.  
   
   
       13 . The polymer of  claim 11 , wherein the metallocene catalyst component is represented by the formulae:  
       Cp A Cp B MX n  and Cp A (A)Cp B MX n    
     wherein each Cp A  and Cp B  are the same or different and are substituted or unsubstituted cyclopentadienyl rings or ligands isolobal to cyclopentadienyl, each bound to M; M is a Group 4, 5, or 6 atom; X is selected from the group consisting of C 1  to C 6  alkyls, C 6  aryls, C 7  to C 12  alkylaryls, fluorinated C 1  to C 6  alkyls, fluorinated C 6  aryls, fluorinated C 7  to C 12  alkylaryls, chlorine and fluorine; n is 1 or 2; and (A) is a divalent bridging group; characterized in that at least one X is a fluorine or fluorinated hydrocarbonyl.  
   
   
       14 . The polymer of  claim 11 , wherein the support material comprises silica.  
   
   
       15 . The polymer of  claim 11 , wherein the support material has a D 90  of less than about 50 microns.  
   
   
       16 . The polymer of  claim 11 , having a density in the range of from about 0.940 to about 0.960 grams per cubic centimeter.  
   
   
       17 . The polymer of  claim 11 , having a melt index ratio in the range of from about 70 to about 200.  
   
   
       18 . The polymer of  claim 11 , having an HLMI in the range of from about 4 to about 15.  
   
   
       19 . A film made from a polymer that is the product of a process comprising: 
 contacting hydrogen and ethylene monomers with a supported multi-transition-metal catalyst composition to form a polyolefin composition; wherein the supported multi-transition-metal catalyst composition comprises:    (1) at least two catalyst components selected from the group consisting of: a nonmetallocene catalyst component and a metallocene catalyst component;    (2) a support material that has a D 50  of less than about 30 microns and a particle size distribution having a D 90 /D 10  ratio of less than about 6; and    (3) an activator.    
   
   
       20 . The film of  claim 19  wherein the film has a Gel Count of less than 30.  
   
   
       21 . The film of  claim 19  wherein the film has a Gel Count of less than 10.  
   
   
       22 . The film of  claim 19 , wherein the support material comprises silica.  
   
   
       23 . The film of  claim 19 , wherein the support material has a D 90  of less than about 50 microns.  
   
   
       24 . The film of  claim 19 , wherein the metallocene catalyst component is represented by the formulae:  
       Cp A Cp B MX n  and Cp A (A)Cp B MX n    
     wherein each Cp A  and Cp B  are the same or different and are substituted or unsubstituted cyclopentadienyl rings or ligands isolobal to cyclopentadienyl, each bound to M; M is a Group 4, 5, or 6 atom; X is selected from the group consisting of C 1  to C 6  alkyls, C 6  aryls, C 7  to C 12  alkylaryls, fluorinated C 1  to C 6  alkyls, fluorinated C 6  aryls, fluorinated C 7  to C 12  alkylaryls, chlorine and fluorine; n is 1 or 2; and (A) is a divalent bridging group; characterized in that at least one X is a fluorine or fluorinated hydrocarbonyl.