The invention relates to an efficient process for the preparation of isoolefin polymers such as polyisobutene or butyl rubber by polymerization of isobutene and optionally further monomers in the presence of an initiator system comprising at least one boron or aluminium compound and at least one tertiary alkyl ether.

In an embodiment, a process to convert a feed includes introducing a feed to an oligomerization catalyst in an oligomerization reactor to form a first reactor effluent; introducing the first reactor effluent to a distillation unit to form a first distillation effluent and a second distillation effluent, the second distillation effluent comprising an oligomer of isobutylene; and introducing the second distillation effluent to a cracking reactor to form a cracking reactor effluent comprising a high purity isobutylene. In another embodiment, an apparatus includes a feed line coupled to a first end of an oligomerization reactor; a first distillation unit coupled with a second end of the oligomerization reactor; a first end of a cracking reactor coupled to a second end of the first distillation unit via a first line; a first end of an isomerization reactor coupled to: a third end of the first distillation unit and the feed line.

In an embodiment, a process to convert a feed includes introducing a feed to an oligomerization catalyst in an oligomerization reactor to form a first reactor effluent; introducing the first reactor effluent to a distillation unit to form a first distillation effluent and a second distillation effluent, the second distillation effluent comprising an oligomer of isobutylene; and introducing the second distillation effluent to a cracking reactor to form a cracking reactor effluent comprising a high purity isobutylene. In another embodiment, an apparatus includes a feed line coupled to a first end of an oligomerization reactor; a first distillation unit coupled with a second end of the oligomerization reactor; a first end of a cracking reactor coupled to a second end of the first distillation unit via a first line; a first end of an isomerization reactor coupled to: a third end of the first distillation unit and the feed line.

Methods of making polyisobutylene and catalyst systems are described. Polyisobutylene compositions and catalyst system compositions are also described. In some embodiments, a method of making a catalyst system includes: providing a support material; calcining the support material; and forming a catalyst system by adding to the support material (a) a mixture comprising BF.sub.3, (b) a mixture comprising BF.sub.3 and a complexing agent, or (c) both. In some embodiments, a method of making a polymer composition includes providing a catalyst system comprising: (a) a support material selected from the group consisting of Al.sub.2O.sub.3, ZrO.sub.2, TiO.sub.2, SnO.sub.2, CeO.sub.2, SiO.sub.2, SiO.sub.2/Al.sub.2O.sub.3, and combinations thereof; and (b) BF.sub.3; providing a feedstock comprising isobutylene; forming a reaction mixture comprising the feedstock and the catalyst system; contacting the isobutylene with the catalyst system; and obtaining a polymer composition.

Methods of making polyisobutylene and catalyst systems are described. Polyisobutylene compositions and catalyst system compositions are also described. In some embodiments, a method of making a catalyst system includes: providing a support material; calcining the support material; and forming a catalyst system by adding to the support material (a) a mixture comprising BF.sub.3, (b) a mixture comprising BF.sub.3 and a complexing agent, or (c) both. In some embodiments, a method of making a polymer composition includes providing a catalyst system comprising: (a) a support material selected from the group consisting of Al.sub.2O.sub.3, ZrO.sub.2, TiO.sub.2, SnO.sub.2, CeO.sub.2, SiO.sub.2, SiO.sub.2/Al.sub.2O.sub.3, and combinations thereof; and (b) BF.sub.3; providing a feedstock comprising isobutylene; forming a reaction mixture comprising the feedstock and the catalyst system; contacting the isobutylene with the catalyst system; and obtaining a polymer composition.

Methods of making polyisobutylene and catalyst systems are described. Polyisobutylene compositions and catalyst system compositions are also described. In some embodiments, a method of making a catalyst system includes: providing a support material; calcining the support material; and forming a catalyst system by adding to the support material (a) a mixture comprising BF.sub.3, (b) a mixture comprising BF.sub.3 and a complexing agent, or (c) both. In some embodiments, a method of making a polymer composition includes providing a catalyst system comprising: (a) a support material selected from the group consisting of Al.sub.2O.sub.3, ZrO.sub.2, TiO.sub.2, SnO.sub.2, CeO.sub.2, SiO.sub.2, SiO.sub.2/Al.sub.2O.sub.3, and combinations thereof; and (b) BF.sub.3; providing a feedstock comprising isobutylene; forming a reaction mixture comprising the feedstock and the catalyst system; contacting the isobutylene with the catalyst system; and obtaining a polymer composition.

A method for preparing polybutene by polymerization of a raw material of a carbon number 4 (C4) compounds having an isobutene amount of 50 to 75% by weight, is disclosed. The raw material of C4 compounds is selected from the group consisting of (a) C4 compound material obtained by adding high purity isobutene to C4 raffinate-1; (b) C4 compound material obtained by adding high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process to C4 raffinate-1; (c) C4 compound material obtained by adding high purity to butane-butene oil (B-B oil); (d) C4 compound material obtained by adding high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process to butane-butene oil (B-B oil); (e) C4 compound material obtained by adding a dilute solvent to high purity isobutene; (f) C4 compound material obtained by adding a dilute solvent to high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process; (g) C4 compound material obtained by adding high purity isobutene to a mixture generated in dehydrogenation reaction that converts isobutane to isobutene; and (h) C4 compound material obtained by adding high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process to a mixture generated in dehydrogenation reaction that converts isobutane to isobutene.

A method for preparing polybutene by polymerization of a raw material of a carbon number 4 (C4) compounds having an isobutene amount of 50 to 75% by weight, is disclosed. The raw material of C4 compounds is selected from the group consisting of (a) C4 compound material obtained by adding high purity isobutene to C4 raffinate-1; (b) C4 compound material obtained by adding high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process to C4 raffinate-1; (c) C4 compound material obtained by adding high purity to butane-butene oil (B-B oil); (d) C4 compound material obtained by adding high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process to butane-butene oil (B-B oil); (e) C4 compound material obtained by adding a dilute solvent to high purity isobutene; (f) C4 compound material obtained by adding a dilute solvent to high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process; (g) C4 compound material obtained by adding high purity isobutene to a mixture generated in dehydrogenation reaction that converts isobutane to isobutene; and (h) C4 compound material obtained by adding high amount isobutene mixture which is generated in an olefin conversion unit (OCU) process to a mixture generated in dehydrogenation reaction that converts isobutane to isobutene.

A novel process can be used for preparing high-reactivity isobutene homo- or copolymers, by polymerizing isobutene or an isobutene-containing monomer mixture in the presence of a polymerization catalyst.

A novel process can be used for preparing high-reactivity isobutene homo- or copolymers, by polymerizing isobutene or an isobutene-containing monomer mixture in the presence of a polymerization catalyst.