Hindered polyalicyclic alkyl catalysts and their use in a gas-phase polymerization reactor

Abstract

Embodiments of the present invention include a method of polymerizing olefins comprising contacting olefins with a catalyst composition made by the process of combining a hindered polyalicyclic alkyl catalyst precursor with a particulate inorganic oxide for a deposition time greater than 2 hours to form a catalyst composition. Embodiments of the present invention also include catalyst compositions comprising a hindered polyalicyclic alkyl catalyst precursor made by the process of combining the hindered polyalicyclic alkyl catalyst precursor with a particulate inorganic oxide for a deposition time greater than 2 hours to form the catalyst composition. In one embodiment, the hindered polyalicyclic alkyl catalyst precursor is formed by first combining an acid, a compound having the formula RX, and a metal oxide selected from the group consisting of Group 3 to Group 10 oxide compounds to produce a catalyst precursor; characterized in that R is selected from the group consisting of hindered polyalicyclic alkyls, and substituted derivatives thereof, and X is selected from the group consisting of any suitable leaving group.

1 - 13 . (canceled) 
     
     
         14 . A catalyst composition comprising a hindered polyalicyclic alkyl catalyst precursor made by the process of combining a hindered polyalicyclic alkyl catalyst precursor with a particulate inorganic oxide for a deposition time greater than 2 hours, followed by contacting with a reducing agent to form a catalyst composition. 
     
     
         15 . The catalyst of  claim 14 , wherein the hindered polyalicyclic alkyl catalyst precursor is formed by first combining an acid, a compound having the formula RX, and a metal oxide selected from the group consisting of Group 3 to Group 10 oxide compounds to produce a catalyst precursor; characterized in that R is selected from the group consisting of hindered polyalicyclic alkyls, and substituted derivatives thereof, and X is selected from the group consisting of any suitable leaving group; 
     
     
         16 . The catalyst of  claim 15 , wherein the metal oxide is selected from the group consisting of Group 4 to Group 6 metal oxides. 
     
     
         17 . The catalyst of  claim 15 , wherein the metal oxide is selected from the group consisting of Group 6 metal oxides. 
     
     
         18 . The catalyst of  claim 15 , wherein the deposition time is greater than 4 hours. 
     
     
         19 . The catalyst of  claim 15 , wherein R is selected from C 7  to C 20  hindered polyalicyclic alkyls and substituted derivatives thereof. 
     
     
         20 . The catalyst of  claim 15 , wherein R is selected from adamantyl and substituted adamantyl. 
     
     
         21 . The catalyst of  claim 15 , wherein the acid is selected from the group consisting of C 2  to C 20  carboxylic acids and substituted derivatives thereof. 
     
     
         22 . The catalyst of  claim 15 , wherein the acid is present in a protic diluent in a concentration from saturated to 0.1 Molar. 
     
     
         23 . The catalyst of  claim 15 , wherein non-protic diluents are absent in the combining step. 
     
     
         24 . A polyolefin produced in a gas-phase reactor using the catalyst of  claim 14 , the polyolefin having an amount of fines less than 4 wt %.