Method for preparing a supported catalyst system and its use in a polymerization process

Abstract

The present invention relates to a supported catalyst composition and a method for making the supported catalyst composition and its use in a process for polymerizing olefin(s). In particular, the invention is directed to a method for making a supported catalyst composition by combining a heated bulky ligand metallocene-type catalyst system with a carrier or an optionally heated carrier.

We claim:  
     
         1 . A method for preparing a supported catalyst system comprising the steps of: 
 (a) heating a composition comprising a bulky ligand metallocene-type catalyst compound to a temperature of from 50° C. to 125° C.; and    (b) combining the heated composition with a carrier.    
     
     
         2 . The method of  claim 1  wherein the carrier is heated.  
     
     
         3 . The method of  claim 1  wherein in step (a) the composition is heated to a temperature in the range of from 75° C. to 100° C.  
     
     
         4 . The method of  claim 2  wherein the carrier is heated to a temperature in the range of from 25° C. to 150° C.  
     
     
         5 . The method of  claim 1  wherein the bulky ligand metallocene-type catalyst compound has a solubility less than 20 weight percent of the bulky ligand metallocene-type catalyst compound in toluene at room temperature (25° C.).  
     
     
         6 . A method for making a supported catalyst system comprising the steps of: 
 (a) forming a reaction product comprising a bulky ligand metallocene-type catalyst compound and an activator;    (b) heating the reaction product to a temperature of from 50° C. to 125° C.;    (c) introducing a carrier, optionally heating the carrier;    (d) combining the heated reaction product with the carrier or optionally the heated carrier.    
     
     
         7 . The method of  claim 6  wherein the reaction product is heated to a temperature in the range from 75° C. to 100° C.  
     
     
         8 . A method for making a supported catalyst system comprising the steps of: 
 (a) heating an activated bulky ligand metallocene-type catalyst product to a temperature of from 50° C. to 125° C.;    (b) heating a carrier; and    (c) combining the heated carrier and the heated activated bulky ligand metallocene-type catalyst.    
     
     
         9 . The method of  claim 8  wherein the activated bulky ligand metallocene-type catalyst is heated to a temperature of from 75° C. to 100° C.  
     
     
         10 . A method for preparing a supported catalyst system comprising the steps of: 
 (a) heating a composition comprising a bulky ligand metallocene-type catalyst compound at a first temperature;    (b) heating a carrier at a second temperature; and    (c) combining (a) and (b) at a third temperature.    
     
     
         11 . The method of  claim 10  wherein the first, second and third temperatures are the same.  
     
     
         12 . The method of  claim 10  wherein the first and second temperatures are the same.  
     
     
         13 . The method of  claim 10  wherein the first temperature is in the range of from 50° C. to 110° C.  
     
     
         14 . A method for preparing a supported catalyst composition comprising the steps of: 
 (a) combining a bulky ligand metallocene-type catalyst compound and an activator at a temperature in the range of from 30° C. to 125° C.; and    (b) introducing a carrier.    
     
     
         15 . The method of  claim 14  wherein the supported catalyst composition is dried or substantially dried to a free flowing powder composition.  
     
     
         16 . The method of  claim 15  wherein the free flowing composition is reslurried in a liquid.  
     
     
         17 . The method of  claim 16  wherein the liquid is mineral oil.  
     
     
         18 . The method of  claim 14  wherein the bulky ligand metallocene-type catalyst compound and activator are combined at a temperature of from 50° C. to 110° C.  
     
     
         19 . The method of  claim 14  wherein the bulky ligand metallocene-type catalyst compound and activator are combined at a temperature of from 60° C. to 100° C.  
     
     
         20 . The method of  claim 14  wherein the bulky ligand metallocene-type catalyst compound and activator are combined at a temperature of from 75° C. to 100° C.