Catalyst compositions containing a metallocene compound, a solid activator, and a co-catalyst, in which the solid activator or the supported metallocene catalyst has a d50 average particle size of 15 to 50 μm and a particle size distribution of 0.5 to 1.5, can be contacted with an olefin in a loop slurry reactor to produce an olefin polymer. A representative ethylene-based polymer produced using the catalyst composition has excellent dart impact strength and low gels, and can be characterized by a HLMI from 4 to 10 g/10 min, a density from 0.944 to 0.955 g/cm.sup.3, a higher molecular weight component with a Mn from 280,000 to 440,000 g/mol, and a lower molecular weight component with a Mw from 30,000 to 45,000 g/mol and a ratio of Mz/Mw ranging from 2.3 to 3.4.

Disclosed are a polyolefin resin composition and a production method using same. The polyolefin resin satisfies the following conditions: (1) melt index (MI2.16, 190° C., under a load of 2.16 kg) is 0.1 to 1.5 g/10 min; (2) density is 0.91 to 0.93 g/cc; (3) polydispersity Index (Mw (weight-average molecular weight)/Mn (number-average molecular weight)) is 3 to 7; (4) Mz (Z-average molecular weight)/Mw (weight-average molecular weight) is 2.3 to 4.5; and (5) COI(Comonomer Orthogonal Index) value calculated by Equation 1 in the specification is 5 to 12. In Equation 1, “SCB number at Mz” represents average number of branches derived from comonomers per 1000 carbon atoms at Z-average molecular weight (Mz), and “SCB number at Mn” represents average number of branches derived from comonomers per 1000 carbon atoms at number-average molecular weight (Mn) based on a molecular weight-comonomer distribution graph.

Disclosed are a polyolefin resin composition and a production method using same. The polyolefin resin satisfies the following conditions: (1) melt index (MI2.16, 190° C., under a load of 2.16 kg) is 0.1 to 1.5 g/10 min; (2) density is 0.91 to 0.93 g/cc; (3) polydispersity Index (Mw (weight-average molecular weight)/Mn (number-average molecular weight)) is 3 to 7; (4) Mz (Z-average molecular weight)/Mw (weight-average molecular weight) is 2.3 to 4.5; and (5) COI(Comonomer Orthogonal Index) value calculated by Equation 1 in the specification is 5 to 12. In Equation 1, “SCB number at Mz” represents average number of branches derived from comonomers per 1000 carbon atoms at Z-average molecular weight (Mz), and “SCB number at Mn” represents average number of branches derived from comonomers per 1000 carbon atoms at number-average molecular weight (Mn) based on a molecular weight-comonomer distribution graph.

Catalyst systems and methods for making and using the same. A method of polymerizing olefins to produce a polyolefin polymer with a multimodal composition distribution, includes contacting ethylene and a comonomer with a catalyst system. The catalyst system includes a first catalyst compound and a second catalyst compound that are co-supported to form a commonly supported catalyst system. The first catalyst compound includes a compound with the general formula (C.sub.5H.sub.aR.sup.1.sub.b)(C.sub.5H.sub.cR.sup.2.sub.d)HfX.sub.2. The second catalyst compound includes at least one of the following general formulas:

##STR00001##

##STR00002##

In both catalyst systems, the R groups can be independently selected from any number of substituents, including, for example, H, a hydrocarbyl group, a substituted hydrocarbyl group, or a heteroatom group, among others.

Catalyst systems and methods for making and using the same. A method of polymerizing olefins to produce a polyolefin polymer with a multimodal composition distribution, includes contacting ethylene and a comonomer with a catalyst system. The catalyst system includes a first catalyst compound and a second catalyst compound that are co-supported to form a commonly supported catalyst system. The first catalyst compound includes a compound with the general formula (C.sub.5H.sub.aR.sup.1.sub.b)(C.sub.5H.sub.cR.sup.2.sub.d)HfX.sub.2. The second catalyst compound includes at least one of the following general formulas:

##STR00001##

##STR00002##

In both catalyst systems, the R groups can be independently selected from any number of substituents, including, for example, H, a hydrocarbyl group, a substituted hydrocarbyl group, or a heteroatom group, among others.

The present disclosure generally relates to catalyst systems, polyethylene compositions, and uses of such compositions in, e.g., films. In an embodiment is provided a film that includes a polyethylene composition, comprising: ethylene and a C.sub.3-C.sub.40 olefin comonomer, the polyethylene composition having at least 75 wt % ethylene content and from 0 wt % to 25 wt % of a C.sub.3-C.sub.40 olefin comonomer content based upon the total weight of the composition as determined by GPC-IR5-LS-VIS, the film having: an average of MD and TD 1% secant modulus of 42,000 psi or greater as determined by ASTM D-882, and a Dart Drop Impact of greater than 400 g/mil, as determined by ASTM D1709. In another embodiment is provided a process for producing a polyethylene composition, comprising: introducing, under first polymerization conditions, ethylene and a C.sub.3-C.sub.40 alpha-olefin to a catalyst system in a reactor, the catalyst system comprising a first catalyst compound, a second catalyst compound, and an activator; and forming a polyethylene composition.

The present disclosure generally relates to catalyst systems, polyethylene compositions, and uses of such compositions in, e.g., films. In an embodiment is provided a film that includes a polyethylene composition, comprising: ethylene and a C.sub.3-C.sub.40 olefin comonomer, the polyethylene composition having at least 75 wt % ethylene content and from 0 wt % to 25 wt % of a C.sub.3-C.sub.40 olefin comonomer content based upon the total weight of the composition as determined by GPC-IR5-LS-VIS, the film having: an average of MD and TD 1% secant modulus of 42,000 psi or greater as determined by ASTM D-882, and a Dart Drop Impact of greater than 400 g/mil, as determined by ASTM D1709. In another embodiment is provided a process for producing a polyethylene composition, comprising: introducing, under first polymerization conditions, ethylene and a C.sub.3-C.sub.40 alpha-olefin to a catalyst system in a reactor, the catalyst system comprising a first catalyst compound, a second catalyst compound, and an activator; and forming a polyethylene composition.

Polymer compositions may include a matrix phase comprising a polypropylene-based polymer; and an elastomeric rubber phase; wherein the polymer composition has melt flow rate (MFR) according to ASTM D1238 at 230° C./2.16 kg equal to or greater than 90 g/10 min and at least one feature selected from (I) an Izod impact resistance according to ASTM D256A at 23° C. equal to or greater than 400 J/m; (II) an instrumented drop impact at −30° C., average total energy, equal to or greater than 17 J; or (III) an instrumented drop impact at −30° C., average percent ductility, equal to or greater than 60%.

Polymer compositions may include a matrix phase comprising a polypropylene-based polymer; and an elastomeric rubber phase; wherein the polymer composition has melt flow rate (MFR) according to ASTM D1238 at 230° C./2.16 kg equal to or greater than 90 g/10 min and at least one feature selected from (I) an Izod impact resistance according to ASTM D256A at 23° C. equal to or greater than 400 J/m; (II) an instrumented drop impact at −30° C., average total energy, equal to or greater than 17 J; or (III) an instrumented drop impact at −30° C., average percent ductility, equal to or greater than 60%.

The present disclosure generally relates to catalyst systems, polyethylene compositions, and uses of such compositions in, e.g., films. In an embodiment is provided a film that includes a polyethylene composition, comprising: ethylene and a C.sub.3-C.sub.40 olefin comonomer, the polyethylene composition having at least 65 wt % ethylene content and from 0 wt % to 35 wt % of a C.sub.3-C.sub.40 olefin comonomer content based upon the total weight of the composition, the film having: an average of MD and TD 1% secant modulus of 43,000 psi or greater, and a Dart Drop Impact Strength of greater than 500 g/mil. In another embodiment is provided a process for producing a polyethylene composition that includes introducing ethylene and a C.sub.3-C.sub.40 alpha-olefin to a catalyst system, the catalyst system comprising a first catalyst compound, a second catalyst compound, and an activator; and forming a polyethylene composition.