Single Reactor Production of Polymers in Gas or Slurry Phase

Abstract

Disclosed are methods for the production of polymers, including random copolymers (RCPs), in single reactor gas or slurry phase polymerization processes, and polymer compositions produced therefrom. The methods enable polymers having low melting temperatures to be made in gas and slurry phase polymerization processes, where they conventionally could not be made in these processes due to stickiness and fouling problems in the reactor.

1 .- 13 . (canceled) 
     
     
         14 . An olefin polymer comprising at least 95 mol % propylene and from 3 to 5 mol % ethylene, based on the total moles of propylene and ethylene in the polymer, and having a melting temperature, Tm (DSC second melt), of less than or equal to 135° C.; wherein after storage for at least four months, the polymer comprises a plurality of particles, and wherein less than 10.0 wt % of the particles have a diameter of more than 4000 μm, based on the total weight of the polymer. 
     
     
         15 . An olefin polymer comprising at least 80 mol % ethylene and from 10 to 20 mol % of at least one C 3  to C 12  alpha-olefin comonomer, based on the total moles of ethylene and C 3  to C 12  alpha-olefin comonomer in the polymer, and having a melting temperature, Tm (DSC second melt), of less than or equal to 110° C.; wherein after storage for at least four months, the polymer comprises a plurality of particles, and wherein less than 10.0 wt % of the particles have a diameter of more than 4000 μm, based on the total weight of in the polymer. 
     
     
         16 . The polymer of  claim 14 , wherein 500 grams of the polymer has an initial pourability value prior to aging or storage of about 120 seconds or less according to ASTM D1895 Method B, modified to use a funnel having a 29 mm bottom opening, a top inner diameter of 73 mm, and a length of the cone-shape portion of the funnel of 50 mm. 
     
     
         17 . The polymer of  claim 14 , wherein 500 grams of the polymer has a pourability value of about 300 seconds or less after aging for at least 7 days at a temperature of about 120° F. according to ASTM D1895 Method B, modified to use a funnel having a 29 mm bottom opening, a top inner diameter of 73 mm, and a length of the cone-shape portion of the funnel of 50 mm. 
     
     
         18 . The polymer of  claim 14 , having a density of from 0.860 to 0.910 g/cc. 
     
     
         19 . The polymer of  claim 14 , wherein the polymer has a melt flow rate, as measured by ASTM D1238, Condition L, 230° C. and 2.16 kg, of from 0.01 to 500 g/10 min. 
     
     
         20 . The polymer of  claim 14 , wherein the polymer has an Mw of at least 400 kg/mol. 
     
     
         21 . The polymer of  claim 15 , wherein the polymer has an Mw/Mn of from 1.5 to 20. 
     
     
         22 . The polymer of  claim 14  wherein 500 grams of the polymer has an initial pourability value prior to aging or storage of about 60 seconds or less according to ASTM D1895 Method B, modified to use a funnel having a 29 mm bottom opening, a top inner diameter of 73 mm, and a length of the cone-shape portion of the funnel of 50 mm. 
     
     
         23 . The polymer of  claim 15 , wherein 500 grams of the polymer has an initial pourability value prior to aging or storage of about 120 seconds or less according to ASTM D1895 Method B, modified to use a funnel having a 29 mm bottom opening, a top inner diameter of 73 mm, and a length of the cone-shape portion of the funnel of 50 mm. 
     
     
         24 . The polymer of  claim 15 , wherein 500 grams of the polymer has a pourability value of 300 seconds or less after aging for at least 7 days at a temperature of about 120° F. according to ASTM D1895 Method B, modified to use a funnel having a 29 mm bottom opening, a top inner diameter of 73 mm, and a length of the cone-shape portion of the funnel of 50 mm. 
     
     
         25 . The polymer of  claim 15 , wherein the polymer has an Mw of at least 400 kg/mol. 
     
     
         26 . The polymer of  claim 15 , wherein 500 grams of the polymer has an initial pourability value prior to aging or storage of about 60 seconds or less according to ASTM D1895 Method B, modified to use a funnel having a 29 mm bottom opening, a top inner diameter of 73 mm, and a length of the cone-shape portion of the funnel of 50 mm.