Transition metal catalyst and formation thereof

Abstract

Catalyst systems and methods of forming the catalyst systems are described herein. The methods generally include contacting a support material with an activator to form a support composition, contacting a component with at least a portion of an aluminum containing compound including TIBAl, wherein the component is selected from the support composition, the transition metal catalyst compound and combinations thereof and contacting the support composition with a transition metal catalyst compound to form a supported catalyst system.

Description

Claims

1. A method of forming a catalyst system comprising: providing a support material;contacting the support material with an activator to form a support composition;providing a single site transition metal catalyst compound;providing a aluminum containing compound, wherein the aluminum containing compound comprises triisobutyl aluminum;contacting a component with at least a portion of the aluminum containing compound, wherein the component is selected from the support composition, the transition metal catalyst compound and combinations thereof; andcontacting the support composition with the transition metal catalyst compound to form a supported catalyst system.

2. The method of claim 1, wherein the support material comprises silica.

3. The method of claim 1, wherein the activator comprises an organic aluminum compound.

4. The method of claim 3, wherein the organic aluminum compound comprises methyl alumoxane.

5. The method of claim 1, wherein the support composition comprises an activator to support material weight ratio of from about 0.05:1 to about 2:1.

6. The method of claim 1, wherein the transition metal catalyst compound comprises a metallocene catalyst.

7. The method of claim 1, wherein the supported catalyst system comprises from about 0.05 wt. % to about 2 wt. % transition metal catalyst compound.

8. The method of claim 1, wherein the at least a portion of the aluminum containing compound comprises a first portion and a second portion, the first portion and the second portion being the same aluminum containing compound or different aluminum containing compounds, and wherein the contacting a component with at least a portion of the aluminum containing compound comprises contacting the support composition with the first portion and contacting the transition metal compound with the second portion.

9. The method of claim 8, wherein the first portion and the second portion are substantially equal.

10. The method of claim 8, wherein the at least a portion of the aluminum containing compound comprises from about 45 wt. % to about 80 wt. % first portion and from about 55 wt. % to about 20 wt. % second portion.

11. The method of claim 8, wherein the first portion contacts the support composition in a weight ratio of from about 0.5:1 to about 2:1.

12. The method of claim 8, wherein the second portion contacts the transition metal catalyst compound in a weight ratio of from about 15:1 to about 30:1.

13. The method of claim 1, wherein the support composition is contacted with the transition metal catalyst component in the presence of an inert solvent.

14. The method of claim 13, wherein the inert solvent comprises isohexane.

15. The method of claim 1 further comprises contacting the supported catalyst system with an olefin monomer to form a polyolefin.

16. The method of claim 15, wherein the polyolefin comprises isotactic polypropylene.

17. The method of claim 15, wherein supported catalyst system results in a productivity that is greater than that of a supported catalyst system absent the aluminum containing compound.

18. The method of claim 15, wherein supported catalyst system results in an productivity that is at least 1.5 times greater than that of a supported catalyst system absent the aluminum containing compound.

19. A supported catalyst system formed by the method of claim 1.

20. The method of claim 1, wherein the aluminum containing compound contacts the support material.

21. The method of claim 1, wherein the aluminum containing compound contacts the transition metal catalyst compound.