Novel catalyst compositions comprising three or more transition metals are effective in increasing catalyst efficiency, reducing polydispersity, and increasing uniformity in molecular weight distribution when used in olefin, and particularly, linear low density polyethylene (LLDPE), polymerizations. The resulting polymers may be used to form differentiated products including, for example, films that may exhibit improved optical and mechanical properties.

Novel catalyst compositions comprising three or more transition metals are effective in increasing catalyst efficiency, reducing polydispersity, and increasing uniformity in molecular weight distribution when used in olefin, and particularly, linear low density polyethylene (LLDPE), polymerizations. The resulting polymers may be used to form differentiated products including, for example, films that may exhibit improved optical and mechanical properties.

Embodiments of the present disclosure are specifically related to LLDPE compositions produced from heterogeneous procatalyst compositions and blown and cast films incorporating these LLDPE compositions.

Embodiments of the present disclosure are specifically related to LLDPE compositions produced from heterogeneous procatalyst compositions and blown and cast films incorporating these LLDPE compositions.

A heterogeneous procatalyst includes a preformed heterogeneous procatalyst and a metal-ligand complex. The preformed heterogeneous procatalyst includes a titanium species and a magnesium chloride (MgCl.sub.2) support. The metal-ligand complex has a structural formula (L).sub.aM(Y).sub.m(XR.sup.2).sub.b, where M is a metal cation; each L is a neutral ligand or (═O); each Y is a halide or (C.sub.1-C.sub.20)alkyl; each XR.sup.2 is an anionic ligand in which X is a heteroatom or a heteroatom-containing functional group and R.sup.2 is (C.sub.1-C.sub.20)hydrocarbyl or (C.sub.1-C.sub.20) heterohydrocarbyl; n is 0, 1, or 2; m is 0-4; and b is 1-6. The metal-ligand complex is overall charge neutral. The heterogeneous procatalyst exhibits improved average molecular weight capability. A catalyst system includes the heterogeneous procatalyst and a cocatalyst. Processes for producing the heterogeneous procatalyst and processes for producing ethylene-based polymers utilizing the heterogeneous procatalyst are also disclosed.

A heterogeneous procatalyst includes a preformed heterogeneous procatalyst and a metal-ligand complex. The preformed heterogeneous procatalyst includes a titanium species and a magnesium chloride (MgCl.sub.2) support. The metal-ligand complex has a structural formula (L).sub.aM(Y).sub.m(XR.sup.2).sub.b, where M is a metal cation; each L is a neutral ligand or (═O); each Y is a halide or (C.sub.1-C.sub.20)alkyl; each XR.sup.2 is an anionic ligand in which X is a heteroatom or a heteroatom-containing functional group and R.sup.2 is (C.sub.1-C.sub.20)hydrocarbyl or (C.sub.1-C.sub.20) heterohydrocarbyl; n is 0, 1, or 2; m is 0-4; and b is 1-6. The metal-ligand complex is overall charge neutral. The heterogeneous procatalyst exhibits improved average molecular weight capability. A catalyst system includes the heterogeneous procatalyst and a cocatalyst. Processes for producing the heterogeneous procatalyst and processes for producing ethylene-based polymers utilizing the heterogeneous procatalyst are also disclosed.

A heterogeneous procatalyst includes a preformed heterogeneous procatalyst and a metal-ligand complex. The preformed heterogeneous procatalyst includes a titanium species and a magnesium chloride (MgCl.sub.2) support. The metal-ligand complex has a structural formula (L).sub.aM(Y).sub.m(XR.sup.2).sub.b, where M is a metal cation; each L is a neutral ligand or (═O); each Y is a halide or (C.sub.1-C.sub.20)alkyl; each XR.sup.2 is an anionic ligand in which X is a heteroatom or a heteroatom-containing functional group and R.sup.2 is (C.sub.1-C.sub.20)hydrocarbyl or (C.sub.1-C.sub.20) heterohydrocarbyl; n is 0, 1, or 2; m is 0-4; and b is 1-6. The metal-ligand complex is overall charge neutral. The heterogeneous procatalyst exhibits improved average molecular weight capability. A catalyst system includes the heterogeneous procatalyst and a cocatalyst. Processes for producing the heterogeneous procatalyst and processes for producing ethylene-based polymers utilizing the heterogeneous procatalyst are also disclosed.

Catalyst systems and solution olefin polymerization processes using a combination of titanium compounds (e.g. halides) with vanadium compounds (e.g. halides or oxyhalides) with tri-n-octyl aluminum (TNOAL) as a co-catalyst, which provides lower in situ oligomerization of olefins that are incorporated into the homopolymer. This feature provides a higher density homopolymer using TNOAL, which enhances polymer properties such as increased moisture barrier and stiffness. Multi-reactor systems and solution olefin polymerization processes comprising this catalyst system.

Catalyst systems and solution olefin polymerization processes using a combination of titanium compounds (e.g. halides) with vanadium compounds (e.g. halides or oxyhalides) with tri-n-octyl aluminum (TNOAL) as a co-catalyst, which provides lower in situ oligomerization of olefins that are incorporated into the homopolymer. This feature provides a higher density homopolymer using TNOAL, which enhances polymer properties such as increased moisture barrier and stiffness. Multi-reactor systems and solution olefin polymerization processes comprising this catalyst system.

A heterogeneous procatalyst includes a titanium species, a magnesium chloride component, and a chlorinating agent having a structure A(C)x(R.sup.1)3-x, where A is aluminum or boron, R.sup.1 is a (C.sub.1-C.sub.30) hydrocarbyl, and x is 1, 2, or 3. The magnesium chloride component may be thermally treated at a temperature greater than 100 C for at least 30 minutes before or after introduction of the chlorinating agent and titanium species to the heterogeneous procatalyst. The heterogeneous procatalyst having the thermally treated magnesium chloride exhibits improved average molecular weight capability. Processes for producing the heterogeneous procatalyst and processes for producing ethylene-based polymers utilizing the heterogeneous procatalyst are also disclosed.