Group 15 containing transition metal catalyst compounds, catalyst systems and their use in a polymerization process

Abstract

The present invention relates to a Group 15 containing metal catalyst compound having a substituted hydrocarbon leaving group, a catalyst system and a supported catalyst system thereof and to a process for polymerizing olefin(s) utilizing them.

1. A process for polymerizing olefin(s) comprising combining said olefin( s ) in the presence of a catalyst system comprising a Group 15 containing bidentate or  tridentate ligated metal catalyst compound, wherein the process is conducted at a temperature from between 50° C. to 200° C., and wherein the catalyst compound is represented by the formulae  formula: 
                 
 wherein M is metal;  
 each X is an aryl substituted alkyl leaving group;  
 y is 0 or 1;  
 n is the oxidation state of M;  
 m is the formal charge of Y, Z and L or of Y, Z, and L′ ;  
 L is a Group 15 element;  
 L′ is a Group 15 element or Group 14 containing group; 
 Y is a Group 15 element;  
 Z is a Group 15 element;  
 R 1  and R 2  are independently a C 1  to C 20  hydrocarbon group, a heteroatom containing group having up to twenty carbon atoms, silicon, germanium, tin, lead, or phosphorus  linear, branched, or cyclic C 2 - C   20    alkyl group;    
 R 3  is absent, a hydrocarbon group, hydrogen, a halogen, or a heteroatom containing group;  
 R 4  and R 5  are independently an alkyl group, an aryl group, a substituted aryl group, a cyclic alkyl group, a substituted cyclic alkyl group, a cyclic arylalkyl group, a substituted cyclic arylalkyl group or a multiple ring system;  
 R 1  and R 2  may be interconnected to each other, and/or R 4  and R 5  may be interconnected to each other; and 
 R 6  and R 7  are independently absent, hydrogen, an alkyl group, halogen, heteroatom or a hydrocarbyl group; and  
 R* is absent, hydrogen, a Group 14 atom containing group, a halogen, or a heteroatom containing group  
 wherein said Group  15  containing tridentate ligated metal catalyst compound is added to a polymerization reactor in one of a slurry, a solution, an emulsion, a dispersion or a suspension, and wherein said Group  15  containing tridentate ligated metal catalyst compound has an activity of at least  641  g polyethylene/mmol catalyst·atm·h.  
 
     
     
       2. The process of  claim 1  wherein R 1  and R 2  are selected from the group consisting of a C 1  to C 20  hydrocarbon group, a heteroatom containing group, silicon, germanium, tin, lead, and phosphorus  a C 2    to C   6    hydrocarbon radical.    
     
     
       3. The process of  claim 1  wherein L or L′ may also be bound to nothing, a hydrogen, a Group 14 atom containing group, a halogen, or a heteroatom containing group, and wherein each of the two Group 15 atoms are also bound to a cyclic group and may optionally be bound to hydrogen, a halogen, a heteroatom, a hydrocarbyl group, or a heteroatom containing group. 
     
     
       4. The process of  claim 1  wherein R 4  and R 5  are represented by the formula: 
                 
 
       wherein R 8  to R 12  are each independently hydrogen, a C 1  to C 40  alkyl group, a halide, a heteroatom, or a heteroatom containing group containing up to 40 carbon atoms, wherein any two R groups may form a cyclic group and/or a heterocyclic group, and wherein the cyclic groups may be aromatic. 
     
     
       5. The process of  claim 4  wherein R 9 , R 10  and R 12   R 8    to R   12  are independently a methyl, ethyl, propyl or butyl group and X is a substituted aryl group having greater than 10 carbon atoms. 
     
     
       6. The process of  claim 4  wherein R 9 , R 10  and R 12   R 8    to R   12  are methyl groups, and R 8  and R 11  are hydrogen and  X is a  an alkyl substituted with an aryl group. 
     
     
       7. The process of  claim 4  wherein L, Y, and Z are nitrogen, R 1  and R 2  are a hydrocarbon radical, R 3  is hydrogen, and R 6  and R 7  are absent. 
     
     
       8. The process of  claim 1  wherein L and Z are independently nitrogen, L′ is a hydrocarbyl radical,  and R 6  and R 7  are absent. 
     
     
       9. The process of  claim 1  wherein the catalyst system is supported on a carrier. 
     
     
       10. The process of  claim 1  wherein the process is a continuous gas phase process. 
     
     
       11. The process of  claim 1  wherein the process is a continuous slurry phase process. 
     
     
       12. The process of  claim 1  wherein the olefin(s) is ethylene or propylene. 
     
     
       13. The process of  claim 1  wherein the olefins are ethylene and at least one other monomer having from 3 to 20 carbon atoms. 
     
     
       14. The process of  claim 1  wherein the catalysts system further comprises an activator.