Fluorinated Impregnated Catalyst Systems and Methods of Forming the Same

Abstract

Methods of forming supported catalyst systems, supported catalyst systems and polymerization processes utilizing supported catalyst systems are described. The methods include providing an inorganic support material, contacting the inorganic support material with a support solvent to form a support solution, and contacting the support solution with a fluorine containing compound (AlF p X 3−p B q ) to form an intermediate. X is Cl, Br or OFF, B is H 2 O, p is from 1 to 3 and q is 0 to 6. The methods include drying and heating the intermediate to at least about 300° C. to form an impregnated support and contacting the impregnated support with a transition metal compound ([L]mM[A]n) to form a supported catalyst system. 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.

1 - 18 . (canceled) 
     
     
         19 . A method of forming a polyolefin comprising:
 providing an inorganic support material;   contacting the inorganic support material with a support solvent to form a support solution;   contacting the support solution with a fluorine containing compound represented by the formula AlF p X 3−p B q  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 H 2 O, p is selected from 1 to 3 and q is selected from 0 to 6;   drying the intermediate to remove the solvent therefrom and heating the intermediate at a temperature of at least about 300° C. to form an impregnated support;   contacting the impregnated support with a transition metal compound to form a supported catalyst system, wherein the transition metal compound is represented by the formula [L] m M[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; and;   contacting the supported catalyst system with an olefin monomer to form a polyolefin.   
     
     
         20 . The method of  claim 19  further comprising contacting the supported catalyst system with an olefin monomer to form a polyolefin, wherein the polyolefin comprises a polymer selected from ethylene, a C 3  or greater alpha olefin, a C 4  or greater conjugated diene, an ethylene-alpha olefin copolymer or combinations thereof. 
     
     
         21 . The method of claim  1  further comprising contacting the supported catalyst system with a propylene monomer to form isotactic polypropylene. 
     
     
         22 . A olefin polymerization process comprising:
 providing an inorganic support material;   contacting the inorganic support material with a support solvent to form a support solution;   contacting the support solution with a fluorine containing compound represented by the formula AlF p X 3−p B q  to impregnate the fluorine containing compound within the inorganic support material and form an intermediate, wherein X is selected from Cl, Br and OFF, B is H 2 O, p is selected from 1 to 3 and q is selected from 0 to 6;   drying the intermediate to remove the solvent therefrom and heating the intermediate at a temperature of at least about 300° C. to form an impregnated support;   contacting the impregnated support with a transition metal compound to form a supported catalyst system, wherein the transition metal compound is represented by the formula [L] m M[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; and   contacting the supported catalyst system with an olefin monomer to form a polyolefin, wherein the polyolefin comprises a polymer selected from ethylene, a C 3  or greater alpha olefin, a C 4  or greater conjugated diene, an ethylene-alpha olefin copolymer or combinations thereof.   
     
     
         23 . The process of  claim 22 , wherein the transition metal compound contacts the impregnated support in-situ. 
     
     
         24 . The process of  claim 22 , wherein the supported catalyst system is formed without producing ammonia.