According to one embodiment, a catalyst system that reduces polymeric fouling may comprise at least one titanate compound, at least one aluminum compound, and at least one antifouling agent or a derivative thereof. The antifouling agent may comprise a structure comprising a central aluminum molecule bound to an R1 group, bound to an R2 group, and bound to an R3 group. One or more of the chemical groups R1, R2, and R3 may be antifouling groups comprising the structure —O((CH.sub.2).sub.nO).sub.mR4, where n is an integer from 1 to 20, m is an integer from 1 to 100, and R4 is a hydrocarbyl group. The chemical groups R1, R2, or R3 that do not comprise the antifouling group, if any, may be hydrocarbyl groups.

A process for making a poly alpha-olefin (PAO) having a relatively high vinylidene content (or combined vinylidene and tri-substituted vinylene content) and a relatively low vinyl and/or di-substituted vinylene content, as well as a relatively low molecular weight. The process includes: contacting a feed containing a C.sub.2-C.sub.32 alpha-olefin with a catalyst system comprising activator and a bis-cyclopentadienyl metallocene compound, typically a cyclopentadienyl-benzindenyl group 4 transition metal compound.

A process for making a poly alpha-olefin (PAO) having a relatively high vinylidene content (or combined vinylidene and tri-substituted vinylene content) and a relatively low vinyl and/or di-substituted vinylene content, as well as a relatively low molecular weight. The process includes: contacting a feed containing a C.sub.2-C.sub.32 alpha-olefin with a catalyst system comprising activator and a bis-cyclopentadienyl metallocene compound, typically a cyclopentadienyl-benzindenyl group 4 transition metal compound.

The present disclosure generally relates to processes to produce alpha-olefin oligomers and poly alpha-olefins. In an embodiment, a process to produce a poly alpha-olefin (PAO) includes introducing a first alpha-olefin and a first catalyst system comprising a metallocene compound into a continuous stirred tank reactor or a continuous tubular reactor under first reactor conditions to form a first reactor effluent. The alpha-olefin is introduced to the reactor at a flow rate of about 100 g/hr or more. The first reactor effluent includes PAO dimer comprising at least 96 mol % of vinylidene and 4 mol % or less of trisubstituted vinylene and disubstituted vinylene, based on total moles of vinylidene, trisubstituted vinylene, and disubstituted vinylene. The method includes introducing the first reactor effluent, a second alpha-olefin and a second catalyst composition comprising an acid catalyst into a second reactor under second reactor conditions to form a second reactor effluent comprising PAO trimer.

The present disclosure generally relates to processes to produce alpha-olefin oligomers and poly alpha-olefins. In an embodiment, a process to produce a poly alpha-olefin (PAO) includes introducing a first alpha-olefin and a first catalyst system comprising a metallocene compound into a continuous stirred tank reactor or a continuous tubular reactor under first reactor conditions to form a first reactor effluent. The alpha-olefin is introduced to the reactor at a flow rate of about 100 g/hr or more. The first reactor effluent includes PAO dimer comprising at least 96 mol % of vinylidene and 4 mol % or less of trisubstituted vinylene and disubstituted vinylene, based on total moles of vinylidene, trisubstituted vinylene, and disubstituted vinylene. The method includes introducing the first reactor effluent, a second alpha-olefin and a second catalyst composition comprising an acid catalyst into a second reactor under second reactor conditions to form a second reactor effluent comprising PAO trimer.

A system and method for producing 1-butene and ultra-high-molecular-weight polyethylene (UHMWPE), including feeding a catalyst, an antifouling co-catalyst, and ethylene to a reactor, and dimerizing ethylene into 1-butene and polymerizing a relatively small portion of the ethylene into UHMWPE. A product slurry including 1-butene and UHMWPE is discharged from reactor and UHMWPE is removed from the product slurry as a coproduct of the product 1-butene. The coproduct UHMWPE may be a byproduct that is a relatively small amount of the product slurry. The quantity of UHMWPE produced may be small in comparison to the quantity of 1-butene produced.

A system and method for producing 1-butene and ultra-high-molecular-weight polyethylene (UHMWPE), including feeding a catalyst, an antifouling co-catalyst, and ethylene to a reactor, and dimerizing ethylene into 1-butene and polymerizing a relatively small portion of the ethylene into UHMWPE. A product slurry including 1-butene and UHMWPE is discharged from reactor and UHMWPE is removed from the product slurry as a coproduct of the product 1-butene. The coproduct UHMWPE may be a byproduct that is a relatively small amount of the product slurry. The quantity of UHMWPE produced may be small in comparison to the quantity of 1-butene produced.

According to one embodiment, a catalyst system that reduces polymeric fouling may comprise at least one titanate compound, at least one aluminum compound, and at least one antifouling agent or a derivative thereof. The antifouling agent may comprise a structure comprising a central aluminum molecule bound to an R1 group, bound to an R2 group, and bound to an R3 group. One or more of the chemical groups R1, R2, and R3 may be antifouling groups comprising the structure —O((CH.sub.2).sub.nO).sub.mR4, where n is an integer from 1 to 20, m is an integer from 1 to 100, and R4 is a hydrocarbyl group. The chemical groups R1, R2, or R3 that do not comprise the antifouling group, if any, may be hydrocarbyl groups.

According to one embodiment, a catalyst system that reduces polymeric fouling may comprise at least one titanate compound, at least one aluminum compound, and at least one antifouling agent or a derivative thereof. The antifouling agent may comprise a structure comprising a central aluminum molecule bound to an R1 group, bound to an R2 group, and bound to an R3 group. One or more of the chemical groups R1, R2, and R3 may be antifouling groups comprising the structure —O((CH.sub.2).sub.nO).sub.mR4, where n is an integer from 1 to 20, m is an integer from 1 to 100, and R4 is a hydrocarbyl group. The chemical groups R1, R2, or R3 that do not comprise the antifouling group, if any, may be hydrocarbyl groups.

According to one embodiment, a catalyst system that reduces polymeric fouling may comprise at least one titanate compound, at least one aluminum compound, and at least one antifouling agent or a derivative thereof. The antifouling agent may comprise a structure comprising a central aluminum molecule bound to an R1 group, bound to an R2 group, and bound to an R3 group. One or more of the chemical groups R1, R2, and R3 may be antifouling groups comprising the structure —O((CH.sub.2).sub.nO).sub.mR4, where n is an integer from 1 to 20, m is an integer from 1 to 100, and R4 is a hydrocarbyl group. The chemical groups R1, R2, or R3 that do not comprise the antifouling group, if any, may be hydrocarbyl groups.