U.S. patent application number 14/270784 was filed with the patent office on 2014-12-25 for processes to produce polyalpha-olefin compositions.
The applicant listed for this patent is ExxonMobil Chemical Patents Inc.. Invention is credited to Lisa S. Baugh, Jo Ann M. Canich, Chia S. Chee, Mark P. Hagemeister, Andrew Jackson, Peijun Jiang, Gordon H. Lee, Frederick Y. Lo, Steven P. Rucker, Shakeel Tirmizi, John F. Walzer, JR., Margaret M. Wu, Norman Yang.
Application Number | 20140378720 14/270784 |
Document ID | / |
Family ID | 35431563 |
Filed Date | 2014-12-25 |
United States Patent
Application |
20140378720 |
Kind Code |
A1 |
Wu; Margaret M. ; et
al. |
December 25, 2014 |
Processes to Produce Polyalpha-Olefin Compositions
Abstract
A process to produce polyalpha-olefins includes contacting a
feed stream of at least one alpha-olefin monomer having 4 to 25
carbon atoms with a metallocene catalyst compound and an activator,
and optionally an alkyl-aluminum compound, under polymerizations
conditions in a reactor. The alpha-olefin monomer is present at 10%
volume or more in the reactor and the feed stream includes less
than 600 ppm of heteroatom containing compounds. The process
further includes obtaining a polyalpha-olefin with at least 50 mole
% C5 to C24 alpha-olefin monomer and kinematic viscosity at
100.degree. C. of 5000 cSt or less.
Inventors: |
Wu; Margaret M.; (Skillman,
NJ) ; Yang; Norman; (Westfield, NJ) ; Baugh;
Lisa S.; (Ringoes, NJ) ; Canich; Jo Ann M.;
(Houston, TX) ; Rucker; Steven P.; (Warren,
NJ) ; Walzer, JR.; John F.; (Seabrook, TX) ;
Lee; Gordon H.; (Newton, PA) ; Lo; Frederick Y.;
(Middlesex, NJ) ; Jackson; Andrew; (Pennington,
NJ) ; Hagemeister; Mark P.; (Houston, TX) ;
Tirmizi; Shakeel; (Matawan, NJ) ; Jiang; Peijun;
(League City, TX) ; Chee; Chia S.; (Baton Rouge,
LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ExxonMobil Chemical Patents Inc. |
Baytown |
TX |
US |
|
|
Family ID: |
35431563 |
Appl. No.: |
14/270784 |
Filed: |
May 6, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11995118 |
May 28, 2008 |
8748361 |
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PCT/US2006/021231 |
Jun 2, 2006 |
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14270784 |
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60700600 |
Jul 19, 2005 |
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Current U.S.
Class: |
585/255 ;
585/271; 585/523 |
Current CPC
Class: |
C10N 2020/04 20130101;
C10N 2020/071 20200501; C10N 2020/065 20200501; C10M 107/10
20130101; C08F 4/65925 20130101; C10N 2020/011 20200501; C10M
2205/0285 20130101; C10M 2205/026 20130101; C08F 110/14 20130101;
C07C 2/02 20130101; C08F 4/65927 20130101; C08F 4/65912 20130101;
C10M 2205/0265 20130101; C10N 2020/013 20200501; C07C 5/05
20130101; C08F 4/65908 20130101; C08F 10/14 20130101; C10M 143/08
20130101; C10N 2020/02 20130101; C10N 2020/019 20200501; C07C 11/02
20130101; C10M 2205/028 20130101; C08F 210/04 20130101; C08F 210/14
20130101; C10N 2020/067 20200501; C10N 2070/00 20130101; C07C 2/34
20130101; C08F 10/14 20130101; C08F 4/65925 20130101; C08F 210/14
20130101; C08F 4/65925 20130101; C08F 110/14 20130101; C08F 2500/03
20130101; C08F 2500/17 20130101; C08F 2500/20 20130101; C08F
2500/02 20130101 |
Class at
Publication: |
585/255 ;
585/523; 585/271 |
International
Class: |
C07C 2/34 20060101
C07C002/34; C07C 5/05 20060101 C07C005/05 |
Claims
1.-120. (canceled)
121. A process to produce a polyalpha-olefin comprising: contacting
a feed stream comprising at least one alpha-olefin monomer having 5
to 24 carbon atoms with a metallocene catalyst compound and an
activator, and optionally an alkyl-aluminum compound, under
polymerization conditions wherein the alpha-olefin monomer having 5
to 24 carbon atoms is present at 10 volume % or more (based upon
the total volume of the catalyst, monomers, and any diluents or
solvents present) in the reactor and where the feed stream
comprises less than 600 ppm of heteroatom containing compounds; and
obtaining a polyalpha-olefin comprising at least 50 mole % of a C5
to C24 alpha-olefin monomer where the polyalpha-olefin has
Kinematic viscosity at 100.degree. C. of 5000 cSt or less.
122. The process of claim 121 wherein the metallocene catalyst
compound is a racemic, bridged metallocene catalyst compound.
123. The process of claim 121 wherein the metallocene comprises one
or more of dimethylsilylbis(cyclopentadienyl)zirconium dichloride;
isopropylidenebis(cyclopentadienyl)zirconium dichloride;
rac-ethylenebis(1-indenyl)zirconium dichloride;
rac-dimethylsilylbis(tetrahydroindenyl)zirconium dichloride;
diphenylmethylidene(cylcopentadienyl)(9-fluorenyl)zirconium
dichloride; bis(indenyl)zirconium dichloride;
cyclopentadienyl(indenyl)zirconium dichloride;
bis(1,2,4-trimethylcyclopentadienyl)zirconium dichloride;
bis(1,3-dimethylcyclopentadienyl)zirconium dichloride;
bis(tetramethylcyclopentadienyl)zirconium dichloride; or
bis(pentamethylcyclopentadienyl)zirconium dichloride.
124. The process of claim 121 where the metallocene is selected
from the group consisting of
rac-dimethylsilylbis(tetrahydroindenyl)ZrX.sub.2,
meso-ethylidenebis(indenyl)ZrX.sub.2, (R.sub.nCp).sub.2ZrX.sub.2 or
(R.sub.mInd).sub.2ZrX.sub.2),
ethylidenebis(R.sub.nCp).sub.2ZrX.sub.2,
dimethylsilylbis(R.sub.nCp).sub.2ZrX.sub.2,
ethylidenebis(R.sub.nInd).sub.2ZrX.sub.2,
dimethylsilylbis(R.sub.nInd).sub.2ZrX.sub.2, wherein X is a
halogen, a substituted or unsubstituted phenyl group, or a C1 to
C20 alkyl, Cp is a cyclopentadienyl ring, R is a C1 to C20 alkyl
group, n is a number denoting the degree of substitution of Cp and
is a number from 0 to 5, Ind is an indenyl ring, m is a number
denoting the degree of substitution of Ind and is a number from 0
to 7.
125. The process of claim 121 further comprising: optionally
treating the polyalpha-olefin to reduce heteroatom containing
compounds to less than 600 ppm; optionally separating the
polyalpha-olefins from solvents or diluents; contacting the
polyalpha-olefin with hydrogen and a hydrogenation catalyst; and
obtaining a polyalpha-olefin having a bromine number less than
1.8.
126. The process of claim 125 wherein the polyalpha-olefin is
treated to remove heteroatom containing compounds prior to
contacting with the hydrogen and or the hydrogenation catalyst and
wherein the treated polyalpha-olefin comprises 10 ppm of heteroatom
containing compounds or less.
127. The process of claim 121 wherein the activator comprises
methylalumoxane and or modified methylalumoxane.
128. The process of claim 121 wherein the activator comprises one
or more of N,N-dimethylanilinium tetra(pentafluorophenyl)borate,
N,N-dialkylphenylanilinium tetra(pentafluorophenyl)borate (where
the alkyl is a C1 to C18 alkyl group), trityl
tetra(pentafluorophenyl)borate, tris(pentafluorophenyl)boron,
tri-alkylammonium tetra(pentafluorophenyl)borate (where the alkyl
is a C1 to C18 alkyl group), tetra-alkylammonium
tetra(pentafluorophenyl)borate (where the alkyl is a C1 to C18
alkyl group).
129. The process of claim 121 wherein the process is a continuous
process comprising: continuously introducing a feed stream
comprising at least 10 mole % of the one or more C5 to C24
alpha-olefins into a reactor, continuously introducing the
metallocene compound and the activator into the reactor, optionally
continuously introducing co-activator into the reactor, and
continuously withdrawing the polyalpha-olefin from the reactor.
130. The process of claim 129 further comprising maintaining a
concentration of hydrogen in the reactor of 1000 ppm or less by
weight.
131. The process of claim 129 wherein the process further
comprises: optionally, continuously treating the polyalpha-olefin
to reduce heteroatom containing compounds to less than 600 ppm;
continuously contacting the polyalpha-olefin with hydrogen and a
hydrogenation catalyst; and continuously obtaining a
polyalpha-olefin having a bromine number less than 1.8.
132. The process of claim 121 wherein two monomers having 5 to 18
carbon atoms are present in the polyalpha-olefin.
133. The process of claim 121 wherein the temperature is from
70.degree. C. to 150.degree. C.
134. The process of claim 133 wherein the pressure is from 1 to 50
atmospheres.
135. The process of claim 134 wherein the feed stream, metallocene
and activator are contacted for a residence time of 1 minute to 1
hour.
136. The process of claim 121 wherein solvent or diluent selected
from the group consisting of butanes, pentanes, hexanes, heptanes,
octanes, nonanes, decanes, undecanes, dodecanes, tridecanes,
tetradecanes, pentadecanes, hexadecanes, benzene, toluene,
o-xylenes, m-xylenes, p-xylenes, ethylbenzene, isopropylbenzene,
and n-butylbenzene is present.
137. The process of claim 121 wherein the metallocene and activator
are combined prior to entering the reactor with an alkylaluminum
compound represented by the formula: R.sub.3Al, wherein each R is
independently a C1 to C20 alkyl group and can be n-alkyl or
iso-alkyl group.
138. The process of claim 137 wherein the R groups are
independently selected from the group consisting of methyl, ethyl,
propyl, isopropyl, butyl, isobutyl, n-butyl, pentyl, isopentyl,
n-pentyl, hexyl, isohexyl, n-hexyl, heptyl, octyl, isocotyl,
n-octyl, nonyl, isononyl, n-nonyl, decyl, isodecyl, n-cecyl,
undecyl, isoundecyl, n-undecyl, dodecyl, isododecyl, and
n-dodecyl.
139. The process of claim 121 wherein ethylene is present in the
monomer feed at from 0.5 to 10 mole %.
140. The process of claim 121 where the feed olefins are contacted
with molecular sieve, activated alumina, silica gel, oxygen
removing catalyst, and or purifying clays to reduce the
heteroatom-containing compounds in the feed to below 10 ppm.
141. The process of claim 121 wherein the polyalpha-olefin is
contacted with hydrogen and a hydrogenation catalyst at a
temperature from 100 to 300.degree. C., for a time period from 5
minutes to 24 hours, and at a hydrogen pressure of from 100 to 2000
psi.
142. The process of claim 141 wherein the hydrogenation catalyst is
selected from the group consisting of one or more of Ni, Pd, Pt,
Co, Rh, Fe, Ru, Os, Cr, Mo, and W, supported on silica, alumina,
clay, titania, zirconia, or mixed metal oxide supports.
143. A process to reduce the mole % of mm triad groups in a
hydrogenated polyalpha-olefin comprising contacting a
polyalpha-olefin with a hydrogenation catalyst and hydrogen and
recovering the hydrogentated polyalpha-olefin having from 1 to 80%
less mm triad groups than the polyalpha-olefin prior to contact
with the hydrogen and hydrogenation catalyst; wherein the
polyalpha-olefin comprises more than 50 mole % of one or more C5 to
C24 alpha-olefin monomers where the polyalpha-olefin has Z mole %
or more of units represented by the formula: ##STR00012## where j,
k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, 20, 21, or 22, n is an integer from 1
to 350, and where Z=8.420*Log(V)-4.048, where V is the kinematic
viscosity of the polyalpha-olefin measured at 100.degree. C. in
cSt.
144. The process of claim 143 wherein the hydrogenated
polyalpha-olefin has from 25 to 70 mole % mm triads.
145. The process of claim 144 wherein the hydrogenated
polyalpha-olefin has a bromine number of less than 0.5.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a process to produce a new class
of poly-alpha-olefins (PAOs) with unique chemical compositions.
More specifically, this invention relates to novel PAOs prepared in
the presence of a metallocene catalyst with an activator and a
process for making PAOs in the presence of a metallocene catalyst
with an activator.
DESCRIPTION OF RELATED ART
[0002] Efforts to improve upon the performance of natural mineral
oil-based lubricants by the synthesis of oligomeric hydrocarbon
fluids have been the subject of important research and development
in the petroleum industry for at least fifty years. These efforts
have led to the relatively recent market introduction of a number
of synthetic lubricants. In terms of lubricant property
improvement, the thrust of the industrial research efforts
involving synthetic lubricants have been towards fluids exhibiting
useful viscosities over a wide temperature range, i.e., improved
viscosity index (VI), while also showing lubricities, thermal and
oxidative stabilities and pour points equal to or better than those
formineral oil.
[0003] The viscosity-temperature relationship of a lubricating oil
is one of the critical criteria which must be considered when
selecting a lubricant for a particular application. The mineral
oils commonly used as a base for single and multigraded lubricants
exhibit a relatively large change in viscosity with a change in
temperature. Fluids exhibiting such a relatively large change in
viscosity with temperature are said to have a low viscosity index.
Viscosity index is an empirical number which indicates the rate of
change in the viscosity of an oil within a given temperature range.
A high VI oil, for example, will thin out at elevated temperatures
more slowly than a low VI oil. Usually, A high VI oil is more
desirable because it has higher viscosity at higher temperature,
which translates into better lubrication and better protection of
the contacting machine elements, preferably at high temperatures
and or at temperatures over a wide range. VI is calculated
according to ASTM method D 2270.
[0004] PAOs comprise a class of hydrocarbons manufactured by the
catalytic oligomerization (polymerization to low-molecular-weight
products) of linear .alpha.-olefin (LAO) monomers. These typically
range from 1-octene to 1-dodecene, with 1-decene being a preferred
material, although oligomeric copolymers of lower olefins such as
ethylene and propylene may also be used, including copolymers of
ethylene with higher olefins as described in U.S. Pat. No.
4,956,122 and the patents referred to therein. PAO products have
achieved importance in the lubricating oil market. Typically there
are two classes of synthetic hydrocarbon fluids (SHF) produced from
linear alpha-olefins, the two classes of SHF being denoted as PAO
and HVI-PAO (high viscosity index PAO's). PAO's and HVI-PAO's of
different viscosity grades are typically produced using promoted
BF.sub.3 or AlCl.sub.3 catalysts.
[0005] Specifically, PAOs may be produced by the polymerization of
olefin feed in the presence of a catalyst such as AlCl.sub.3,
BF.sub.3, or BF.sub.3 complexes. Processes for the production of
PAOs are disclosed, for example, in the following patents: U.S.
Pat. Nos. 3,149,178; 3,382,291; 3,742,082; 3,769,363; 3,780,128;
4,172,855 and 4,956,122, which are fully incorporated by reference.
PAOs are also discussed in: Will, J. G. Lubrication Fundamentals,
Marcel Dekker: New York, 1980.
[0006] Subsequent to polymerization, the PAO lubricant range
products are typically hydrogenated in order to reduce the residual
unsaturation, generally to a level of greater than 90%. HVI-PAO's
may also be conveniently made by the polymerization of an
alpha-olefin in the presence of a polymerization catalyst such as
Friedel-Crafts catalysts. These include, for example, aluminum
trichloride, boron trifluoride, aluminum trichloride or boron
trifluoride promoted with water, with alcohols such as ethanol,
propanol, or butanol, with carboxylic acids, or with esters such as
ethyl acetate or ethyl propionate or ether such as diethyl ether,
diisopropyl ether, etc. For example, the methods disclosed by U.S.
Pat. No. 4,149,178 or U.S. Pat. No. 3,382,291 may be conveniently
used herein. Other descriptions of PAO synthesis are found in the
following U.S. Patents: U.S. Pat. No. 3,742,082 (Brennan); U.S.
Pat. No. 3,769,363 (Brennan); U.S. Pat. No. 3,876,720 (Heilman);
U.S. Pat. No. 4,239,930 (Allphin); U.S. Pat. No. 4,367,352 (Watts);
U.S. Pat. No. 4,413,156 (Watts); U.S. Pat. No. 4,434,408 (Larkin);
U.S. Pat. No. 4,910,355 (Shubkin); U.S. Pat. No. 4,956,122 (Watts);
and U.S. Pat. No. 5,068,487 (Theriot).
[0007] Another class of HVI-PAOs may be prepared by the action of a
supported, reduced chromium catalyst with an alpha-olefin monomer.
Such PAOs are described in U.S. Pat. No. 4,827,073 (Wu); U.S. Pat.
No. 4,827,064 (Wu); U.S. Pat. No. 4,967,032 (Ho et al.); U.S. Pat.
No. 4,926,004 (Pelrine et al.); and U.S. Pat. No. 4,914,254
(Pelrine). Commercially available PAOs include SpectraSyn.TM. 2, 4,
5, 6, 8, 10, 40, 100 and SpectraSyn Ultra.TM. 150, SpectraSyn
Ultra.TM. 300, SpectraSyn Ultra.TM. 1000, etc. (ExxonMobil Chemical
Company, Houston Tex.).
[0008] Synthetic PAOs have found wide acceptability and commercial
success in the lubricant field for their superiority to mineral
based lubricants. In terms of lubricant property improvement,
industrial research efforts on synthetic lubricants have led to PAO
fluids exhibiting useful viscosities over a wide range of
temperature, i.e., improved viscosity index, while also showing
lubricity, thermal and oxidative stability and pour point equal to
or better than mineral oil. These relatively new synthetic
lubricants lower mechanical friction, enhancing mechanical
efficiency over the full spectrum of mechanical loads and do so
over a wider range of operating conditions than mineral oil
lubricants.
[0009] Performance requirements of lubricants are becoming
increasingly stringent. New PAOs with improved properties, such as
high viscosity index (VI), low pour point, high shear stability,
improved wear performance, increased thermal and oxidative
stability, and or wider viscosity range, are needed to meet new
performance requirements for lubricants. New methods to provide
such new PAOs with improved properties are also needed.
[0010] Efforts have been made to prepare various PAOs using
metallocene catalyst systems. Examples include U.S. Pat. No.
6,706,828 (equivalent to US 2004/0147693), where PAOs are produced
from meso-forms of certain metallocene catalysts under high
hydrogen pressure. Comparative example D of U.S. Pat. No.
6,706,828, however, uses
rac-dimethylsilylbis(2-methyl-indenyl)zirconium dichloride in
combination with methylalumoxane (MAO) at 100.degree. C. in the
presence of hydrogen to produce polydecene having a reported
Kinematic Viscosity at 100.degree. C. (KV.sub.100) of 116 cSt, a
Kinematic Viscosity at 40.degree. C. (KV.sub.40) of 1039 cSt, a VI
of 214, an iodine number of 2.8, an Mw of 7084, an Mn of 2906, an
Mw/Mn of 2.4, and a Tg of -72.4.degree. C. Likewise, WO 02/14384
discloses, among other things, in examples J and K the use of
rac-ethyl-bis(indenyl)zirconium dichloride or
rac-dimethylsilyl-bis(2-methyl-indenyl) zircomium dichloride in
combination with MAO at 40.degree. C. (at 200 psi hydrogen or 1
mole of hydrogen) to produce isotactic polydecene reportedly having
a Tg of -73.8.degree. C., a KV.sub.100 of 702 cSt, and a VI of 296;
or to produce polydecene reportedly having a Tg of -66.degree. C.,
a KV.sub.100 of 1624, and a VI of 341, respectively. Further WO
99/67347 discloses in example 1 the use of ethylidene
bis(tetrahydroindenyl)zirconium dichloride in combination with MAO
at 50.degree. C. to produce a polydecene having an Mn of 11,400 and
94% vinylidene double bond content.
[0011] Others have made various PAOs, such as polydecene, using
various metallocene catalysts not typically known to produce
polymers or oligomers with any specific tacticity. Examples include
WO 96/23751, EP 0 613 873, U.S. Pat. No. 5,688,887, U.S. Pat. No.
6,043,401, WO 03/020856 (equivalent to US 2003/0055184), U.S. Pat.
No. 6,548,724 (equivalent to US 2001/0041817 and U.S. Pat. No.
6,548,723), U.S. Pat. No. 5,087,788, U.S. Pat. No. 6,414,090, U.S.
Pat. No. 6,414,091, U.S. Pat. No. 4,704,491, U.S. Pat. No.
6,133,209, and U.S. Pat. No. 6,713,438.
[0012] To date however, PAO's made with metallocenes have not found
wide applicability in the marketplace, particularly the lubricant
marketplace, due to inefficient process, cost and property
deficits. The instant invention address such and other needs by
providing new PAO's and or HVI-PAO's having excellent property
combinations and an improved process to produce them.
SUMMARY OF INVENTION
[0013] This invention relates to a polyalpha-olefin comprising more
than 50 mole % of one or more C.sub.5 to C.sub.24 alpha-olefin
monomers where the polyalpha-olefin has:
[0014] a) 40 mole % or more of mm triads,
[0015] b) a Bromine number of Y or greater, where Y is equal to
89.92*(V).sup.-0.5863, where V is the kinematic viscosity of the
polyalpha-olefin in cSt measured at 100.degree. C., and
[0016] c) 1,2 disubstituted olefins present at 7 mole % or more,
preferably present at Z mole % or more, where Z=8.420*Log(V)-4.048
where V is the kinematic viscosity of the polyalpha-olefin in cSt
measured at 100.degree. C.
[0017] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has:
[0018] a) 40 mole % or more of mm triads,
[0019] b) a Bromine number of 1.8 or less, and
[0020] c) Z mole % or more of units represented by the formula:
##STR00001##
where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, or 22; n is an integer
from 1 to 350; and where Z=8.420*Log(V)-4.048, where V is the
kinematic viscosity of the polyalpha-olefin measured at 100.degree.
C. in cSt
[0021] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has: [0022] a) 40
mole % or more of mm triads, [0023] b) a Bromine number of Y or
greater, where Y is equal to 89.92*(V).sup.-0.5863, where V is the
kinematic viscosity of the polyalpha-olefin in cSt measured at
100.degree. C., and [0024] c) 1,2 disubstituted olefins, preferably
present at Z mole % or more of units represented by the
formula:
##STR00002##
[0024] where the olefinic 1,2-disubstituted carbons will be
positioned between Ca and Cb or occasionally between Cb and Cc, and
where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, or 22; n is an integer
from 1 to 350; and where Z=8.420*Log(V)-4.048, where V is the
kinematic viscosity of the polyalpha-olefin measured at 100.degree.
C. in cSt.
[0025] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has:
[0026] a) less than 40 mole % of mm triads,
[0027] b) a Bromine number of 1.8 or less, and
[0028] c) Z mole % or more of units represented by the formula:
##STR00003##
where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, or 16, n is an integer from 1 to 350, and where
Z=8.420*Log(V)-4.048, where V is the kinematic viscosity of the
polyalpha-olefin measured at 100.degree. C. in cSt
[0029] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has Z mole % or
more of units represented by the formula:
##STR00004##
where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, or 22, n is an integer
from 1 to 350, and where Z=8.420*Log(V)-4.048, where V is the
kinematic viscosity of the polyalpha-olefin measured at 100.degree.
C. in cSt
[0030] Alternatively, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has:
[0031] a) 40 mole % or less of mm triads,
[0032] b) a Bromine number of Y or greater, where Y is equal to
89.92*(V).sup.-0.5863, where V is the kinematic viscosity in cSt
measured at 100.degree. C., and
[0033] c) 1,2 disubstituted olefins present at Z mole % or more
where Z=8.420*Log(V)-4.048 where V is the kinematic viscosityof the
polyalphaolefin in cSt measured at 100.degree. C.
[0034] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has 40 mole % or
more of mm triads and less than 300 ppm of a Group 4 metal.
Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers where the polyalpha-olefin has 40 mole % or
more of mm triads and less than 1000 ppm of a Group 13 metal,
preferably less than 1000 pm of aluminum and/or boron. Alternately,
this invention relates to a polyalpha-olefin comprising more than
50 mole % of one or more C5 to C24 alpha-olefin monomers where the
polyalpha-olefin has 40 mole % or more of mm triads and less than
1000 ppm of aluminum and boron.
[0035] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers, where the polyalpha-olefin has 40 mole % or
more of mm triads and less than 100 ppm of a Group 13 metal.
[0036] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers, where the polyalpha-olefin has 40 mole % or
more of mm triads and less than 1000 ppm of aluminum.
[0037] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % of one or more C5 to C24
alpha-olefin monomers, where the polyalpha-olefin has 40 mole % or
more of mm triads and less than 600 ppm of aluminum.
[0038] Alternatively, this invention relates to a hydrogenated
polyalpha-olefin comprising more than 50 mole % of one or more C5
to C24 alpha-olefin monomers, where the polyalpha-olefin has mm
triads ranging from 95% to 20% mm triads and less than 1000 ppm of
group 13 metals, preferably less than 1000 ppm of aluminum and/or
boron.
[0039] Alternatively, this invention relates to a hydrogenated
polyalpha-olefin comprising more than 50 mole % of one or more C5
to C24 alpha-olefin monomers, where the polyalpha-olefin has mm
triads ranging from 95% to 20% mm triads and less than 1000 ppm of
group 13 metals, preferably less than 1000 ppm of aluminum and/or
boron.
[0040] Alternately, this invention relates to a polyalpha-olefin
comprising more than 50 mole % C5 to C24 alpha-olefin monomers and
having an Mw of 100,000 or less and an Mw/Mn of greater than 1 and
less than 2.5.
[0041] This invention also relates to process to produce such
polyalpha-olefins comprising contacting the C5 to C20 monomers with
a metallocene catalyst (preferably a racemic metallocene catalyst),
an activator (preferably an alumoxane and or a non-coordinating
anion) and, optionally an alkylaluminum compound.
[0042] This invention also relates to process to produce such
polyalpha-olefins comprising contacting C5 to C20 monomers with a
metallocene catalyst and an activator, preferably a racemic
metallocene catalyst with an alumoxane or NCA as activator, or a
substituted metallocene catalyst with an NCA activator, or a meso
metallocene with an NCA activator. In all cases, optionally a
co-activator such as an alkylaluminum compound mat be used.
[0043] Further, these polyalpha-olefins (and any polyalpha-olefins
described herein) may be hydrogenated by contacting the
polyalpha-olefin with hydrogen and a hydrogenation catalyst. This
hydrogenation step is often used to reduce the bromine number
and/or to modify the amount of mm triads in the final
poly-alpha-olefins.
BRIEF DESCRIPTION OF THE FIGURES
[0044] FIG. 1 is a graph of bromine number versus KV100 for certain
PAO's from the examples and U.S. Pat. No. 6,706,828.
[0045] FIG. 2 is a graph of mole % B components (by GC or Proton
NMR) versus KV100 for certain PAO's from the examples and
comparative examples 1-4.
[0046] FIG. 3 is a possible reaction scheme for the formation of
A'', B'', A and B components, including head to head
connection.
[0047] FIG. 4 is a gas chromatograph for the C30H62 fraction of
example 31.
[0048] FIG. 5 is a possible reaction scheme for the independent
synthesis of C30H62B.
[0049] FIG. 6 is a proton-NMR of the olefinic region of the Example
35 PAO.
[0050] FIG. 7 is a graph of traction results for the Example 32
hydrogenated PAO compared to SpectraSyn 100 and SpectraSyn Ultra
150.
[0051] FIG. 8 is a carbon 13 NMRs pectra of 8B.sub.8 region of
Example 36.
[0052] FIG. 9 is a methyl branch and C.sub.3+ branch region of the
carbon 13 NMR spectrum for Example 56.
[0053] FIG. 10 is a graph of methyls per 1000 carbons versus KV100
for Examples 36, 37, 38, 39, 40, 41 and Comparative examples 1 to
4
DETAILED DESCRIPTION OF THE INVENTION
[0054] As used herein, the new numbering scheme for the Periodic
Table of the [0055] Elements is used as set out in CHEMICAL AND
ENGINEERING NEWS, 63(5), 27 (1985).
[0056] For purposes of this invention and the claims thereto, when
a polymer or oligomer is referred to as comprising an olefin, the
olefin present in the polymer or oligomer is the polymerized or
oligomerized form of the olefin, respectively. Likewise the use of
the term polymer is meant to encompass homopolymers and copolymers,
where copolymers include any polymer having two or more chemically
distinct monomers. Likewise the use of the term oligomer is meant
to encompass homooligomers and cooligomers, where cooligomers
include any oligomer or having two or more chemically distinct
monomers.
[0057] For the purposes of this invention and the claims thereto
the term "Polyalpha-olefin," "polyalphaolefin," or "PAO" includes
homooligomers, cooligomers, homopolymers and copolymers of
alpha-olefin monomers.
[0058] For the purposes of this invention and the claims thereto
the active species in a catalytic cycle may comprise the neutral or
ionic forms of the catalyst.
[0059] The term "catalyst system" is defined to mean a catalyst
precursor/activator pair, such as a metallocene/activator pair.
When "catalyst system" is used to describe such a pair before
activation, it means the unactivated catalyst (precatalyst)
together with an activator and, optionally, a co-activator (such as
a trialkylaluminum compound). When it is used to describe such a
pair after activation, it means the activated catalyst and the
activator or other charge-balancing moiety. Additionally, the
catalyst system may optionally comprise a co-activator and/or other
charge-balancing moiety.
[0060] "Catalyst precursor" is also often referred to as
precatalyst, catalyst, precursor, metallocene, transition metal
compound, unactivated catalyst, or transition metal complex. These
words are used interchangeably. Activator and cocatalyst are also
used interchangeably. A scavenger is a compound that is typically
added to facilitate oligomerization or polymerization by scavenging
impurities. Some scavengers may also act as activators and may be
referred to as co-activators. A co-activator which is not a
scavenger may also be used in conjunction with an activator in
order to form an active catalyst with a transition metal compound.
In some embodiments, a co-activator can be pre-mixed with the
transition metal compound to form an alkylated transition metal
compound, also referred to as an alkylated catalyst compound or
alkylated metallocene.
[0061] For purposes of this invention and the claims thereto
noncoordinating anion (NCA) is defined to mean an anion which
either does not coordinate to the catalyst metal cation or that
coordinates only weakly to the metal cation. An NCA coordinates
weakly enough that a neutral Lewis base, such as an olefinically or
acetylenically unsaturated monomer, can displace it from the
catalyst center. Any metal or metalloid that can form a compatible,
weakly coordinating complex with the catalyst metal cation may be
used or contained in the noncoordinating anion. Suitable metals
include, but are not limited to, aluminum, gold, and platinum.
Suitable metalloids include, but are not limited to, boron,
aluminum, phosphorus, and silicon. A subclass of non-coordinating
anions comprises stoichiometric activators, which can be either
neutral or ionic. The terms ionic activator, and stoichiometric
ionic activator can be used interchangeably. Likewise, the terms
neutral stoichiometric activator and Lewis acid activator can be
used interchangeably.
[0062] In addition, a reactor is any container(s) in which a
chemical reaction occurs.
Polyalpha-Olefins
[0063] In a preferred embodiment, this invention relates to
polyalpha-olefins (PAO's) comprising more than 50 mole % of one or
more C5 to C24 alpha-olefin monomers, preferably 55 mole % or more,
preferably 60 mole % or more, preferably 65 mole % or more,
preferably 70 mole % or more, preferably 75 mole % or more,
preferably 80 mole % or more, preferably 85 mole % or more,
preferably 90 mole % or more, preferably 95 mole % or more,
preferably 100 mole % based on the total moles of monomers present
in the polyalpha-olefin, as measured by Carbon-13 NMR.
[0064] In another embodiment this invention further relates to
PAO's having 40 mole % or more of mm triads, preferably 45% or
more, preferably 50% or more, preferably 55% or more, preferably
60% or more, preferably 65% or more, preferably 70% or more,
preferably 75% or more, preferably 80% or more, preferably 85% or
more, preferably 90% or more, preferably 95% or more, as determined
by Carbon-13 Nuclear Magnetic Resonance (NMR) spectroscopy
according to the procedure below.
[0065] In another embodiment, the polyalphaolefins according to the
present invention have at least about 84 mole % mm triads. In yet
other embodiments, the PAO's have at least about 98 mole % mm
triads. In one embodiment, the polyalphaolefins according to the
present invention have a ratio of mm to mr triads ranging from
about 49 to about 1.0. In one embodiment, the preferred range is
from 1.0 to 10.0, or from 2 to 49, or from 2 to 18, with more
preferred ranges of from 1.0 to 8 or from 8 to 49, as measured by
Carbon 13 NMR.
[0066] In another embodiment, this invention further related to
hydrogenated PAO's having 90% or less mm triads, preferably 70% mm
triads or less, preferably 50% mm triads or less, preferably 30% or
less mm triads, or preferably 10% mm triads or less.
[0067] In another embodiment, the hydrogenated polyalphaolefins
according to the present invention have a ratio of mm to mr triads
of less than 1, with preferred range from 0.01 to 0.9.
[0068] NMR spectroscopy provides key structural information about
the synthesized polymers. Proton NMR analysis of the unhydrogenated
PAO gives a quantitative breakdown of the olefinic structure types
(viz. vinyl, 1,2-disubstituted, trisubstituted, and vinylidene). As
noted above, Carbon-13 NMR is used to determine tacticity of the
polyalphaolefins of the present invention--quantitatively in some
cases, and qualitatively in others. Carbon-13 NMR can be used to
determine the concentration of the triads, denoted mm (meso, meso),
mr (meso, racemic) and rr (racemic, racemic), as well as molar
composition of the sample. The concentrations of these triads
defines whether the polymer is isotactic, atactic or syndiotactic.
Spectra for a PAO sample are acquired in the following manner.
Approximately 100-1000 mg of the PAO sample is dissolved in 2-3 ml
of chloroform-d for Carbon 13 analysis. Approximately -10 mg/ml
(solvent basis) of chromium acetylacetonate relaxation agent,
Cr(acac).sub.3, is added to the sample to enhance the data
acquisition rate. Analysis of the spectra is performed according to
the paper by Kim, I.; Zhou, J.-M.; and Chung, H. Journal of Polymer
Science: Part A: Polymer Chemistry 2000, 38 1687-1697, augmented by
the identification and integration of end group resonances, and
removal of their contributions to the peaks used in the analysis.
The deconvolutions are executed with Acorn NMR Inc.'s NutsPro NMR
data analysis software, using an 85/15 Lorentzian/Gaussian
lineshape. The component peaks are lumped together into clusters
according to the mm, mr, and rr triad assignments, and fit with a
Bernoullian distribution. The adjustable parameter for these fits
is P.sub.r, the fraction of monomer added with racemic
stereochemistry. For details of going from a set of triad
measurements (such as described by Kim above) to a statistical
model (such as the Bernoullian) see "Polymer Sequence
Determination, James C. Randall, Academic Press, New York,
1977"
[0069] In another embodiment, any of the polyalpha-olefins produced
herein preferably have a Bromine number of Y or greater, where Y is
equal to 89.92.times.(V).sup.-0.5863, where V is the Kinematic
Viscosity at 100.degree. C. (KV.sub.100) of the polyalpha-olefin
and where KV.sub.100 is measured according to ASTM D 445,
preferably a bromine number of Y+1 or greater, preferably Y+2 or
greater, preferably Y+3 or greater, preferably Y+4 or greater,
where Bromine number is measured by ASTM D 1159.
[0070] In another embodiment, any of the polyalpha-olefins produced
herein preferably have 1,2 disubstituted olefins present at 7 mole
% or more, based upon the total moles of all monomers present in
the poly-alpha-olefin as measured by Proton NMR, preferably 8 mole
% or more, preferably 9 mole % or more, preferably 10 mole % or
more, preferably 15 mole % or more.
[0071] In another embodiment, any of the polyalpha-olefins produced
herein preferably have 1,2-disubstituted olefins present at Z mole
% or more as measured by Proton-NMR, where Z=8.420*Log(V)-4.048,
where V is the kinematic viscosity of the polyalpha-olefin measured
at 100.degree. C. in cSt In another embodiment, any of the
polyalpha-olefins produced herein preferably have a Bromine number
of 1.8 or less as measured by ASTM D 1159, preferably 1.7 or less,
preferably 1.6 or less, preferably 1.5 or less, preferably 1.4 or
less, preferably 1.3 or less, preferably 1.2 or less, preferably
1.1 or less, preferably 1.0 or less, preferably 0.5 or less,
preferably 0.1 or less.
[0072] In another embodiment, any of the polyalpha-olefins produced
herein are hydrogenated and have a Bromine number of 1.8 or less as
measured by ASTM D 1159, preferably 1.7 or less, preferably 1.6 or
less, preferably 1.5 or less, preferably 1.4 or less, preferably
1.3 or less, preferably 1.2 or less, preferably 1.1 or less,
preferably 1.0 or less, preferably 0.5 or less, preferably 0.1 or
less.
[0073] In another embodiment, any of the polyalpha-olefins
described herein preferably have Z mole % or more of units
represented by the formula:
##STR00005##
where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, or 22, n is an integer
from 1 to 350 (preferably 1 to 300, preferably 5 to 50), as
measured by proton NMR and where Z=8.420*Log(V)-4.048, where V is
the kinematic viscosity of the polyalpha-olefin measured at
100.degree. C. in cSt, preferably Z is =0.990*V.sup.(0.627). The
proton NMR analysis (used to measure 1,2-disubstitutions and the
units represented by the formula above) is performed by dissolving
the sample in appropriate deuterated solvent (e.g. chloroform-d),
and acquiring a pulse-acquire experiment of sufficient
signal-to-noise ratio to allow integration of the olefin region
(approximately 6 ppm-4.6 ppm). The spectra are acquired at a
temperature of 50.degree. C., with the temperature chosen to ensure
complete sample dissolution (if the sample is not completely
dissolved at 50.degree. C., then the temperature is raised slowly
until the sample is completely dissolved). The aliphatic region of
the proton spectrum comprises the signal from the saturated
components, and the olefinic region from the unsaturated end of the
polymer. In cases where multiple alphaolefins are copolymerized, it
may be possible to determine the composition of the polymer from
the branch methyl resonances of the differing alphaolefin branches.
This composition determination can be executed if the methyl peaks
(resonating between 1.0 and 0.6 ppm) are sufficiently resolved to
allow direct integration, or spectral deconvolution. The olefinic
region can be integrated piecewise according to the chemical shift
assignments tabulated below:
TABLE-US-00001 Chemical shift Number of Olefin type range (ppm)
protons Vinyl 5.7-5.9 1 4.8-5.3 2 1,2-disubstituted 5.3-5.6 2
Trisubstituted 4.8-5.3 1 Vinylidene (1,1-disubstituted) 4.6-4.8
2
The olefin subintegrals are corrected for the proton multiplicity
of the contributing species, and for overlapping contributions
(e.g. both vinyl and trisubstituted olefins in the 5.3-4.8 ppm
region). The integral values resulting from this correction can
then be normalized to give the mole-percentage of each olefin
class. Comparison of the corrected integral values with the
aliphatic integral intensity (also multiplicity-corrected) can be
used to determine the olefin concentrations on an absolute basis
(e.g. olefins per 1000 carbons).
[0074] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 300 ppm of Group 4
metals (preferably Ti, Hf or Zr), preferably less than 200 ppm,
preferably less than 100 ppm, preferably less than 50 ppm,
preferably less than 10 ppm, as measured by ASTM 5185.
[0075] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 300 ppm of Ti,
preferably less than 200 ppm, preferably less than 100 ppm,
preferably less than 50 ppm, preferably less than 10 ppm, as
measured by ASTM 5185.
[0076] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 300 ppm of Hf,
preferably less than 200 ppm, preferably less than 100 ppm,
preferably less than 50 ppm, preferably less than 10 ppm, as
measured by ASTM 5185.
[0077] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 300 ppm of Zr,
preferably less than 200 ppm, preferably less than 100 ppm,
preferably less than 50 ppm, preferably less than 10 ppm, as
measured by ASTM 5185.
[0078] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 100 ppm of Group 13
metals (preferably B or Al), preferably less than 50 ppm,
preferably less than 10 ppm, as measured by ASTM 5185.
[0079] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 100 ppm of boron,
preferably less than 50 ppm, preferably less than 10 ppm, as
measured by ASTM 5185.
[0080] In another embodiment, any of the polyalpha-olefins
described herein preferably have less than 600 ppm of aluminum,
preferably less than 500 ppm, preferably less than 600 ppm,
preferably less than 300 ppm, preferably less than 300 ppm,
preferably less than 10 ppm, preferably less than 50 ppm,
preferably less than 10 ppm, as measured by ASTM 5185.
[0081] In another embodiment, any of the polyalpha-olefins
described herein preferably have an Mw (weight average molecular
weight) of 100,000 or less, preferably between 100 and 80,000,
preferably between 250 and 60,000, preferably between 280 and
50,000, preferably between 336 and 40,000 g/mol. (Preferred Mw's
include those from 224 to 55,100, preferably from 392 to 30,000,
preferably 800 to 24,000, preferably 2,000 to 37,5000 g/mol.
Alternately preferred Mw's include 224 to about 6790 and 224 to
about 2720).
[0082] In another embodiment, any of the polyalpha-olefins
described herein preferably have an Mn (number average molecular
weight) of 50,000 or less, preferably between 200 and 40,000,
preferably between 250 and 30,000, preferably between 500 and
20,000 g/mol. (Preferred Mn's include those from 280 to 10,000,
preferably form 280 to 4000. Alternately preferred Mn's include
those from 200 to 20,900, preferably 280, to 10,000, preferably 200
to 7000, preferably 200 to 2000, preferably 280 to 2900, preferably
280 to 1700, preferably 200 to 500.)
[0083] In another embodiment, any of the polyalpha-olefins
described herein preferably have an Mw/Mn of greater than 1 and
less than 5, preferably less than 4, preferably less than 3,
preferably less than 2.5, preferably less than 2. Alternately any
of the polyalpha-olefins described herein preferably have an Mw/Mn
of between 1 and 2.5, alternately between 1 and 3.5.
[0084] The Mw, Mn and Mz are measured by GPC method using a column
for medium to low molecular weight polymers, tetrahydrofuran as
solvent and polystyrene as calibration standard, correlated with
the fluid viscosity according to a power equation.
[0085] This relationship of Mw vs. 100.degree. C. viscosity in cSt
for fluids prepared in this invention using 1-decene as feed is as
following: Mw=352.41.times.(100.degree. C. vis in cSt).sup.0.5997.
Similarly, the relationship of Mw vs. 100.degree. C. viscosity in
cSt for fluids prepared in this invention using 1-hexene as feed is
as following: Mw=234.85*(V).sup.0.6165 where V is the kinematic
viscosity measured at 100.degree. C. in cSt When other
alpha-olefins are used as feed, this Mw vs. 100.degree. C.
viscosity relationship may change slightly. It is expected similar
type of relationship will hold.
[0086] Unless otherwise indicated Mw values reported herein are GPC
values and not calculated from KV100.
[0087] In a preferred embodiment of this invention, any PAO
described herein may have a pour point of less than 0.degree. C.
(as measured by ASTM D 97), preferably less than -10.degree. C.,
preferably less than -20.degree. C., preferably less than
-25.degree. C., preferably less than -30.degree. C., preferably
less than -35.degree. C., preferably less than -50.degree. C.,
preferably between -10 and -80.degree. C., preferably between
-15.degree. C. and -70.degree. C.
[0088] In a preferred embodiment of this invention, any PAO
described herein may have a kinematic viscosity (at 40.degree. C.
as measured by ASTM D 445) from about 4 to about 50,000 cSt,
preferably from about 5 cSt to about 30,000 cSt at 40.degree. C.,
alternately from about 4 to about 100,000 cSt, preferably from
about 6 cSt to about 50,000 cSt, preferably from about 10 cSt to
about 30,000 cSt at 40.degree. C.
[0089] In another embodiment according to the present invention,
any polyalpha olefin described herein may have a kinematic
viscosity at 100.degree. C. from about 1.5 to about 5,000 cSt,
preferably from about 2 to about 3,000 cSt, preferably from about 3
cSt to about 1,000 cSt, more preferably from about 4 cSt to about
1,000 cSt, and yet more preferably from about 8 cSt to about 500
cSt as measured by ASTM D445. The PAOs preferably have viscosities
in the range of 2 to 500 cSt at 100.degree. C. in one embodiment,
and from 2 to 3000 cSt at 100.degree. C. in another embodiment, and
from 3.2 to 300 cSt in another embodiment. Alternately, the
polyalpha-olefin has a KV.sub.100 of less than 200 cSt.
[0090] In another embodiment according to the present invention any
polyalpha olefin described herein may have a kinematic viscosity at
100.degree. C. from 3 to 10 cSt and a flash point of 150.degree. C.
or more, preferably 200.degree. C. or more (as measured by ASTM D
56).
[0091] In another embodiment according to the present invention any
polyalpha olefin described herein may havea dielectric constant of
2.5 or less (1 kHz at 23.degree. C. as determined by ASTM D
924).
[0092] In another embodiment according to the present invention any
polyalpha olefin described herein may have a specific gravity of
0.75 to 0.96 g/cm.sup.3, preferably 0.80 to 0.94 g/cm.sup.3.
[0093] The PAO's prepared herein, particularly those of low
viscosity (such as those with a KV.sub.100 of 10 cSt or less), are
especially suitable for high performance automotive engine oil
formulations either by themselves or by blending with other fluids,
such as Group II, Group II+, Group III, Group III+ or lube base
stocks derived from hydroisomerization of wax fractions from
Fisher-Tropsch hydrocarbon synthesis from CO/H2 syn gas, or other
Group IV or Group V base stocks. PAOs having KV.sub.100's from 3
cSt to 8 cSt are also preferred grades for high performance
automotive engine oil or industrial oil formulations. The PAO's of
40 to 1000 cSt made in this invention are desirable for use as
blend stock with Gr I, II, III, III+ or GTL derived lube base
stocks for use in industrial and automotive engine or gear oil,
especially certain high KV.sub.100 grades of 3 to 1000 cSt which
are especially desirable for use as blend stock with Gr I, II, III,
III+ or GTL derived lube base stocks for use in industrial and
automotive engine or gear oil. They are also suitable for use in
personal care applications, such as blends with soaps, detergents,
other emollients, for use in personal care creams, lotions, sticks,
shampoos, detergents, etc.
[0094] In another embodiment the PAO's have KV.sub.100's ranging
from about 42 to about 3045 cSt In another embodiment the PAO's
have KV.sub.100's ranging from about 32 to about 102 cSt
[0095] In another embodiment according to the present invention,
any polyalpha olefin described herein may have a viscosity index
(VI) of 100 or more, preferably 120 or more, preferably 130 or
more, alternately, form 120 to 450, alternately from 100 to 400,
alternately from 120 to 380, alternately from 100 to 300,
alternately from 140 to 380, alternately from 180 to 306,
alternately from 252 to 306, alternately the viscosity index is at
least about 165, alternately at least about 187, alternately at
least about 200, alternately at least about 252. For many lower
viscosity fluids made from 1-decene or 1-decene equivalent feeds
(KV.sub.100 of 3 to 10 cSt), the preferred VI range is from 100 to
180. Viscosity index is determined according to ASTM Method D
2270-93 [1998].
[0096] All kinematic viscosity values reported for fluids herein
are measured at 100.degree. C. unless otherwise noted. Dynamic
viscosity can then be obtained by multiplying the measured
kinematic viscosity by the density of the liquid. The units for
kinematic viscosity are in m.sup.2/s, commonly converted to cSt or
centistokes (lcSt=10.sup.-6 m.sup.2/s or 1 cSt=1 mm.sup.2/sec).
[0097] One embodiment according to the present invention is a new
class of poly-alpha-olefins, which have a unique chemical
composition characterized by a high percentage of unique
head-to-head connections at the end position of the polymer chain
and a high degree of stereo-regularity. The new poly-alpha-olefins
when used by themselves or blended with other fluids have unique
lubrication properties. The term "head-to-head connection" refers
to a connection formed on at least one end of the PAO oligomer or
polymer in which the penultimate olefin inserted 1,2 and the last
olefin inserted 2,1 into the oligomer or polymer chain, as
illustrated in the lower scheme in FIG. 3.
[0098] Another embodiment according to the present invention is a
new class of hydrogenated poly-alpha-olefins having a unique
chemical composition which is characterized by a high percentage of
unique head-to-head connection at the end position of the polymer
and by a reduced degree tacticity compared to the product before
hydrogenation. The new poly-alpha-olefins when used by itself or
blended with another fluid have unique lubrication properties.
[0099] The PAO's produced according to this invention are typically
dimers, trimers, tetramers, or higher oligomers of one or more C5
to C24 olefin monomers, preferably one or more C5 to C24
alpha-olefin monomers, preferably one or more C5 to C24 linear
alpha-olefin monomers. Alternatively, an alpha-olefin with alkyl
substitutent at least 2 carbons away from the olefinic double bond
can also be used. Typically, the PAO's produced herein are usually
a mixture of many different oligomers. The smallest oligomers from
these alpha-olefins have carbon number ranging from C10 to C20.
These small oligmers are usually too light for most high
performance fluids application. They are usually separated from the
higher oligomers with carbon number of greater than C20, for
example C24 and higher which are more preferred as high performance
fluids. These separated C10 to C20 oligomer olefins or the
corresponding paraffins after hydrogenation can be used in
specialty applications, such as drilling fluids, solvents, paint
thinner, etc with excellent biodegradability, toxicity,
viscosities, etc. The high performance fluid fraction in the C20,
or C30 and higher fractions typically have lower viscosities making
them beneficial for some applications, such as better fuel economy,
better biodegradability, better low temperature flow properties, or
lower volatility. The higher viscosity product, usually have much
higher average degree of polymerization have very low amount of C20
or C30 component. These high viscosity fluids are excellent blend
stocks for lube application to improve the viscosity. Because of
their usually narrow molecular weight distribution, they have
superior shear stability. Because of their unique chemical
composition, they have excellent viscometrics and unexpected low
traction properties. These higher viscosity PAO can be used as
superior blend stocks. They can be blend stocks with any of the Gr
I, II, III, III+, GTL and Gr V fluids to give the optimum
viscometrics, solvency, high and low temperature lubricity, etc.
When further blended with proper additives, including antioxidants,
anitwear additives, friction modifiers, dispersants, detergents,
corrosion inhibitors, defoamants, extreme pressure additives, seal
swell additives, and optionally viscosity modifiers, etc.
Description of typical additives can be found in the book
"Lubricant Additives" Chemistry and Applications, ed. L. R.
Rudnick, Marcel Dekker, Inc., New York, 2003.
Process
[0100] One embodiment of the present invention discloses an
improved process to produce a new class of poly-alpha-olefins
having unique chemical compositions. This improved process employs
metallocene catalysts together with one or more activators (such as
an alumoxane or a non-coordinating anion). The metallocene catalyst
can be a bridged or unbridged, substituted or unsubstituted
cyclopentadienyl, indenyl or fluorenyl compound. One preferred
class of catalysts are highly substituted metallocenes that give
high catalyst productivity and higher product viscosity. Another
preferred class of metallocenes are bridged and substituted
cyclopentadienes. Another preferred class of metallocenes are
bridged and substituted indenes or fluorenes. One aspect of the
processes described herein also includes treatment of the feed
olefins to remove catalyst poisons, such as peroxides, oxygen,
sulfur, nitrogen-containing organic compounds, and or acetylenic
compounds. This treatment is believed to increase catalyst
productivity, typically more than 5 fold, preferably more than 10
fold.
[0101] In a preferred embodiment, this invention relates to a
process to produce a polyalpha-olefin comprising:
[0102] 1) contacting at least one alpha-olefin monomer having 5 to
24 carbon atoms with a racemic metallocene compound (preferably a
highly substituted compound) and an activator under polymerization
conditions wherein hydrogen, if present, is present at a partial
pressure of 200 psi (1379 kPa) or less, based upon the total
pressure of the reactor (preferably 150 psi (1034 kPa) or less,
preferably 100 psi (690 kPa) or less, preferably 50 psi (345 kPa)
or less, preferably 25 psi (173 kPa) or less, preferably 10 psi (69
kPa) or less (alternately the hydrogen, if present is present in
the reactor at 1000 ppm or less by weight, preferably 750 ppm or
less, preferably 500 ppm or less, preferably 250 ppm or less,
preferably 100 ppm or less, preferably 50 ppm or less, preferably
25 ppm or less, preferably 10 ppm or less, preferably 5 ppm or
less), and wherein the alpha-olefin monomer having 5 to 24 carbon
atoms is present at 10 volume % or more based upon the total volume
of the catalyst/activator/co-activator solutions, monomers, and any
diluents or solvents present in the reaction; and
[0103] 2) obtaining a polyalpha-olefin, optionally hydrogenating
the PAO, and obtaining a PAO, comprising at least 50 mole % of a C5
to C24 alpha-olefin monomer, wherein the polyalpha-olefin has a
kinematic viscosity at 100.degree. C. of 5000 cSt or less, and the
polyalpha-olefin comprises Z mole % or more of units represented by
the formula:
##STR00006##
where j, k and m are each, independently, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, or 22, n is an integer
from 1 to 350, and where Z=8.420*Log(V)-4.048, where V is the
Kinematic viscosity of the polyalpha-olefin measured at 100.degree.
C. in cSt.
[0104] In an alternate embodiment, this invention relates to a
process to produce a polyalpha-olefin comprising:
[0105] 1) contacting a feed stream comprising at least one
alpha-olefin monomer having 5 to 24 carbon atoms with a metallocene
catalyst compound and a non-coordinating anion activator or
alkylalumoxane activator, and optionally an alkyl-aluminum
compound, under polymerization conditions wherein the alpha-olefin
monomer having 5 to 24 carbon atoms is present at 10 volume % or
more based upon the total volume of the
catalyst/activator/co-activator solution, monomers, and any
diluents or solvents present in the reactor and where the feed
alpha-olefin, diluent or solvent stream comprises less than 300 ppm
of heteroatom containing compounds; and obtaining a
polyalpha-olefin comprising at least 50 mole % of a C5 to C24
alpha-olefin monomer where the polyalpha-olefin has a kinematic
viscosity at 100.degree. C. of 5000 cSt or less. Preferably,
hydrogen, if present is present in the reactor at 1000 ppm or less
by weight, preferably 750 ppm or less, preferably 500 ppm or less,
preferably 250 ppm or less, preferably 100 ppm or less, preferably
50 ppm or less, preferably 25 ppm or less, preferably 10 ppm or
less, preferably 5 ppm or less.
[0106] In an alternate embodiment, this invention relates to a
process to produce a polyalpha-olefin comprising:
[0107] 1) contacting a feed stream comprising at least one
alpha-olefin monomer having 5 to 24 carbon atoms with a metallocene
catalyst compound and a non-coordinating anion activator or
alkylalumoxane activator, and optionally an alkyl-aluminum
compound, under polymerization conditions wherein the alpha-olefin
monomer having 5 to 24 carbon atoms is present at 10 volume % or
more based upon the total volume of the
catalyst/activator/co-activator solution, monomers, and any
diluents or solvents present in the reactor and where the feed
alpha-olefin, diluent or solvent stream comprises less than 300 ppm
of heteroatom containing compounds which; and obtaining a
polyalpha-olefin comprising at least 50 mole % of a C5 to
C24alpha-olefin monomer where the polyalpha-olefin has a kinematic
viscosity at 100.degree. C. of 5000 cSt or less;
[0108] 2) isolating the lube fraction polymers and then contacting
this lube fraction with hydrogen under typical hydrogenation
conditions with hydrogenation catalyst to give fluid with bromine
number below 1.8, or alternatively, isolating the lube fraction
polymers and then contacting this lube fraction with hydrogen under
more severe conditions with hydrogenation catalyst to give fluid
with bromine number below 1.8 and with reduce mole % of mm
components than the unhydrogenated polymers.
[0109] Alternately, in any process described herein hydrogen, if
present, is present in the reactor at 1000 ppm or less by weight,
preferably 750 ppm or less, preferably 500 ppm or less, preferably
250 ppm or less, preferably 100 ppm or less, preferably 50 ppm or
less, preferably 25 ppm or less, preferably 10 ppm or less,
preferably 5 ppm or less.
[0110] Alternately, in any process described herein hydrogen, if
present, is present in the feed at 1000 ppm or less by weight,
preferably 750 ppm or less, preferably 500 ppm or less, preferably
250 ppm or less, preferably 100 ppm or less, preferably 50 ppm or
less, preferably 25 ppm or less, preferably 10 ppm or less,
preferably 5 ppm or less.
[0111] Unless otherwise stated all pressures in psi are psig.
Metallocene Catalyst Compounds
[0112] For purposes of this invention and the claims thereto, the
terms "hydrocarbyl radical," "hydrocarbyl," and hydrocarbyl group"
are used interchangeably throughout this document. Likewise the
terms "group," "radical," and "substituent" are also used
interchangeably throughout this document. For purposes of this
disclosure, "hydrocarbyl radical" is defined to be a
C.sub.1-C.sub.100 radical and may be linear, branched, or cyclic.
When cyclic, the hydrocarbon radical may be aromatic or
non-aromatic. "Hydrocarbon radical" is defined to include
substituted hydrocarbyl radicals, halocarbyl radicals, substituted
halocarbyl radicals, silylcarbyl radicals, and germylcarbyl
radicals as these terms are defined below. Substituted hydrocarbyl
radicals are radicals in which at least one hydrogen atom has been
substituted with at least one functional group such as NR*.sub.2,
OR*, SeR*, TeR*, PR*.sub.2, AsR*.sub.2, SbR*.sub.2, SR*, BR*.sub.2,
SiR*.sub.3, GeR*.sub.3, SnR*.sub.3, PbR*.sub.3 and the like or
where at least one non-hydrocarbon atom or group has been inserted
within the hydrocarbyl radical, such as --O--, --S--, --Se--,
--Te--, --N(R*)-, .dbd.N--, --P(R*)-, .dbd.P--, --As(R*)-,
.dbd.As--, --Sb(R*)-, .dbd.Sb--, --B(R*)-, .dbd.B--,
--Si(R*).sub.2-, --Ge(R*).sub.2-, --Sn(R*).sub.2-, --Pb(R*).sub.2--
and the like, where R* is independently a hydrocarbyl or halocarbyl
radical, and two or more R* may join together to form a substituted
or unsubstituted saturated, partially unsaturated or aromatic
cyclic or polycyclic ring structure.
[0113] Halocarbyl radicals are radicals in which one or more
hydrocarbyl hydrogen atoms have been substituted with at least one
halogen (e.g. F, Cl, Br, I) or halogen-containing group (e.g.
CF.sub.3).
[0114] Substituted halocarbyl radicals are radicals in which at
least one halocarbyl hydrogen or halogen atom has been substituted
with at least one functional group such as NR*.sub.2, OR*, SeR*,
TeR*, PR*.sub.2, AsR*.sub.2, SbR*.sub.2, SR*, BR*.sub.2,
SiR*.sub.3, GeR*.sub.3, SnR*.sub.3, PbR*.sub.3 and the like or
where at least one non-carbon atom or group has been inserted
within the halocarbyl radical such as --O--, --S--, --Se--, --Te--,
--N(R*)-, .dbd.N--, --P(R*)-, .dbd.P--, --As(R*)-, .dbd.As--,
--Sb(R*)-, .dbd.Sb--, --B(R*)-, .dbd.B--, --Si(R*).sub.2-,
--Ge(R*).sub.2-, --Sn(R*).sub.2-, --Pb(R*).sub.2-- and the like,
where R* is independently a hydrocarbyl or halocarbyl radical
provided that at least one halogen atom remains on the original
halocarbyl radical. Additionally, two or more R* may join together
to form a substituted or unsubstituted saturated, partially
unsaturated or aromatic cyclic or polycyclic ring structure.
[0115] Silylcarbyl radicals (also called silylcarbyls) are groups
in which the silyl functionality is bonded directly to the
indicated atom or atoms. Examples include SiH.sub.3, SiH.sub.2R*,
SiHR*.sub.2, SiR*.sub.3, SiH.sub.2(OR*), SiH(OR*).sub.2,
Si(OR*).sub.3, SiH.sub.2(NR*.sub.2), SiH(NR*.sub.2).sub.2,
Si(NR*.sub.2).sub.3, and the like where R* is independently a
hydrocarbyl or halocarbyl radical and two or more R* may join
together to form a substituted or unsubstituted saturated,
partially unsaturated or aromatic cyclic or polycyclic ring
structure.
[0116] Germylcarbyl radicals (also called germylcarbyls) are groups
in which the germyl functionality is bonded directly to the
indicated atom or atoms. Examples include GeH.sub.3, GeH.sub.2R*,
GeHR*.sub.2, GeR.sup.5.sub.3, GeH.sub.2(OR*), GeH(OR*).sub.2,
Ge(OR*).sub.3, GeH.sub.2(NR*.sub.2), GeH(NR*.sub.2).sub.2,
Ge(NR*.sub.2).sub.3, and the like where R* is independently a
hydrocarbyl or halocarbyl radical and two or more R* may join
together to form a substituted or unsubstituted saturated,
partially unsaturated or aromatic cyclic or polycyclic ring
structure.
[0117] Polar radicals or polar groups are groups in which a
heteroatom functionality is bonded directly to the indicated atom
or atoms. They include heteroatoms of groups 1-17 of the periodic
table (except carbon and hydrogen) either alone or connected to
other elements by covalent bonds or other interactions such as
ionic bonds, van der Waals forces, or hydrogen bonding. Examples of
functional heteroatom containing groups include carboxylic acids,
acid halides, carboxylic esters, carboxylic salts, carboxylic
anhydrides, aldehydes and their chalcogen (Group 14) analogues,
alcohols and phenols, ethers, peroxides and hydroperoxides,
carboxylic amides, hydrazides and imides, amidines and other
nitrogen analogues of amides, nitriles, amines and imines, azos,
nitros, other nitrogen compounds, sulfur acids, selenium acids,
thiols, sulfides, sulfoxides, sulfones, phosphines, phosphates,
other phosphorus compounds, silanes, boranes, borates, alanes,
aluminates. Functional groups may also be taken broadly to include
organic polymer supports or inorganic support material such as
alumina, and silica. Preferred examples of polar groups include
NR*.sub.2, OR*, SeR*, TeR*, PR*.sub.2, AsR*.sub.2, SbR*.sub.2, SR*,
BR*.sub.2, SnR*.sub.3, PbR*.sub.3 and the like where R* is
independently a hydrocarbyl, substituted hydrocarbyl, halocarbyl or
substituted halocarbyl radical as defined above and two R* may join
together to form a substituted or unsubstituted saturated,
partially unsaturated or aromatic cyclic or polycyclic ring
structure.
[0118] In using the terms "substituted or unsubstituted
cyclopentadienyl ligand", "substituted or unsubstituted indenyl
ligand", and "substituted or unsubstituted tetrahydroindenyl
ligand", the substitution to the aforementioned ligand may be
hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted
halocarbyl, silylcarbyl, or germylcarbyl. The substitution may also
be within the ring giving heterocyclopentadienyl ligands,
heteroindenyl ligands or heterotetrahydroindenyl ligands, each of
which can additionally be substituted or unsubstituted.
[0119] In some embodiments, the hydrocarbyl radical is
independently selected from methyl, ethyl, ethenyl, and isomers of
propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl,
dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl,
octadecyl, nonadecyl, eicosyl, heneicosyl, docosyl, tricosyl,
tetracosyl, pentacosyl, hexacosyl, heptacosyl, octacosyl,
nonacosyl, triacontyl, propenyl, butenyl, pentenyl, hexenyl,
heptenyl, octenyl, nonenyl, decenyl, undecenyl, dodecenyl,
tridecenyl, tetradecenyl, pentadecenyl, hexadecenyl, heptadecenyl,
octadecenyl, nonadecenyl, eicosenyl, heneicosenyl, docosenyl,
tricosenyl, tetracosenyl, pentacosenyl, hexacosenyl, heptacosenyl,
octacosenyl, nonacosenyl, triacontenyl, propynyl, butynyl,
pentynyl, hexynyl, heptynyl, octynyl, nonynyl, decynyl, undecynyl,
dodecynyl, tridecynyl, tetradecynyl, pentadecynyl, hexadecynyl,
heptadecynyl, octadecynyl, nonadecynyl, eicosynyl, heneicosynyl,
docosynyl, tricosynyl, tetracosynyl, pentacosynyl, hexacosynyl,
heptacosynyl, octacosynyl, nonacosynyl, triacontynyl, butadienyl,
pentadienyl, hexadienyl, heptadienyl, octadienyl, nonadienyl, and
decadienyl. Also included are isomers of saturated, partially
unsaturated and aromatic cyclic and polycyclic structures wherein
the radical may additionally be subjected to the types of
substitutions described above. Examples include phenyl,
methylphenyl, dimethylphenyl, ethylphenyl, diethylphenyl,
propylphenyl, dipropylphenyl, benzyl, methylbenzyl, naphthyl,
anthracenyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl,
methylcyclohexyl, cycloheptyl, cycloheptenyl, norbornyl,
norbornenyl, adamantyl and the like. For this disclosure, when a
radical is listed, it indicates that radical type and all other
radicals formed when that radical type is subjected to the
substitutions defined above. Alkyl, alkenyl and alkynyl radicals
listed include all isomers including where appropriate cyclic
isomers, for example, butyl includes n-butyl, 2-methylpropyl,
1-methylpropyl, tert-butyl, and cyclobutyl (and analogous
substituted cyclopropyls); pentyl includes n-pentyl, cyclopentyl,
1-methylbutyl, 2-methylbutyl, 3-methylbutyl, 1-ethylpropyl, and
neopentyl (and analogous substituted cyclobutyls and cyclopropyls);
butenyl includes E and Z forms of 1-butenyl, 2-butenyl, 3-butenyl,
1-methyl-1-propenyl, 1-methyl-2-propenyl, 2-methyl-1-propenyl and
2-methyl-2-propenyl (and cyclobutenyls and cyclopropenyls). Cyclic
compound having substitutions include all isomer forms, for
example, methylphenyl would include ortho-methylphenyl,
meta-methylphenyl and para-methylphenyl; dimethylphenyl would
include 2,3-dimethylphenyl, 2,4-dimethylphenyl, 2,5-dimethylphenyl,
2,6-diphenylmethyl, 3,4-dimethylphenyl, and 3,5-dimethylphenyl.
Examples of cyclopentadienyl and indenyl ligands are illustrated
below as anionic ligands.
The ring numbering scheme is also
##STR00007##
illustrated.
[0120] A similar numbering and nomenclature scheme is used for
heteroindenyl as illustrated below where Z and Q independently
represent the heteroatoms O, S, Se, or Te, or heteroatom groups,
NR', PR', AsR', or SbR' where R' is hydrogen, or a hydrocarbyl,
substituted hydrocarbyl, halocarbyl, substituted halocarbyl,
silylcarbyl, or germylcarbyl substituent. The number scheme shown
below is for heteroindenyl ligands that are bridged to another
ligand via a bridging group.
##STR00008##
Examples include: Cyclopenta[b]thienyl (Z=S) Cyclopenta[b]furanyl
(Z=O) Cyclopenta[b]selenophenyl (Z=Se) Cyclopenta[b]tellurophenyl
(Z=Te) 6-Methyl-cyclopenta[b]pyirolyl(Z=N-Me)
6-Methyl-cyclopenta[b]phospholyl(Z=P-Me)
6-Methyl-cyclopenta[b]arsolyl (Z=As-Me)
6-Methyl-cyclopenta[b]stibolyl (Z=Sb-Me) Examples include:
Cyclopenta[c]thienyl(Z=S) Cyclopenta[c]furanyl (Z=O)
Cyclopenta[c]selenophenyl (Z=Se) Cyclopenta[c]tellurophenyl (Z=Te)
5-Methyl-cyclopenta[c]pyrrolyl(Z=N-Me)
5-Methyl-cyclopenta[c]phospholyl(Z=P-Me)
5-Methyl-cyclopenta[c]arsolyl (Z=As-Me)
5-Methyl-cyclopenta[c]stibolyl (Z=Sb-Me) [0121] A similar numbering
and nomenclature scheme is used for heterocyclopentadienyl rings as
illustrated below where G and J independently represent the
heteroatoms N, P, As, Sb or B. For these ligands when bridged to
another ligand via a bridging group, the one position is usually
chosen to be the ring carbon position where the ligand is bonded to
the bridging group, hence a numbering scheme is not illustrated
below.
##STR00009##
[0121] Examples include: [0122] Azacyclopentadiene (G=N) [0123]
Phosphacyclopentadiene (G=P) [0124] Stibacyclopentadiene (G=Sb)
[0125] Arsacyclopentadiene (G=As) [0126] Boracyclopentadiene (G=B)
[0127] Depending on the position of the bridging ligand, the
numbering for the following ligands will change; 1,3 and 1,2 are
only used in this case to illustrate the position of the
heteroatoms relative to one another.
##STR00010##
[0127] Examples include:
1,3-Diazacyclopentadiene (G=J=N)
1,3-Diphosphacyclopentadiene (G=J=P)
1,3-Distibacyclopentadiene (G=J=Sb)
1,3-Diarsacyclopentadiene (G=J=As)
1,3-Diboracyclopentadiene (G=J=B)
1,3-Azaphosphacyclopentadiene (G=N; J=P)
1,3-Azastibacyclopentadiene (G=N; J=Sb)
1,3-Azarsacyclopentadiene (G=N; J=As)
1,3-Azaboracyclopentadiene (G=N; J=B)
1,3-Arsaphosphacyclopentadiene (G=As; J=P)
1,3-Arsastibacyclopentadiene (G=As; J=Sb)
1,3-Arsaboracyclopentadiene (G=As; J=B)
1,3-Boraphosphacyclopentadiene (G=B; J=P)
1,3-Borastibacyclopentadiene (G=B; J=Sb)
1,3-Phosphastibacyclopentadiene (G=P; J=Sb)
[0128] Examples include:
1,2-Diazacyclopentadiene (G=J=N)
1,2-Diphosphacyclopentadiene (G=J=P)
1,2-Distibacyclopentadiene (G=J=Sb)
1,2-Diarsacyclopentadiene (G=J=As)
1,2-Diboracyclopentadiene (G=J=B)
1,2-Azaphosphacyclopentadiene (G=N; J=P)
1,2-Azastibacyclopentadiene (G=N; J=Sb)
1,2-Azarsacyclopentadiene (G=N; J=As)
1,2-Azaboracyclopentadiene (G=N; J=B)
1,2-Arsaphosphacyclopentadiene (G=As; J=P)
1,2-Arsastibacyclopentadiene (G=As; J=Sb)
1,2-Arsaboracyclopentadiene (G=As; J=B)
1,2-Boraphosphacyclopentadiene (G=B; J=P)
1,2-Borastibacyclopentadiene (G=B; J=Sb)
1,2-Phosphastibacyclopentadiene (G=P; J=Sb)
[0129] A "ring heteroatom" is a heteroatom that is within a cyclic
ring structure. A "heteroatom substituent" is heteroatom containing
group that is directly bonded to a ring structure through the
heteroatom. A "bridging heteroatom substituent" is a heteroatom or
heteroatom group that is directly bonded to two different ring
structures through the heteroatom. The terms "ring heteroatom",
"heteroatom substituent", and "bridging heteroatom substituent" are
illustrated below where Z and R' are as defined above. It should be
noted that a "heteroatom substituent" can be a "bridging heteroatom
substituent" when R' is additionally defined as the ligand "A".
##STR00011##
[0130] A "ring carbon atom" is a carbon atom that is part of a
cyclic ring structure. By this definition, an indenyl ligand has
nine ring carbon atoms; a cyclopentadienyl ligand has five ring
carbon atoms.
[0131] Transition metal compounds have symmetry elements and belong
to symmetry groups. These elements and groups are well established
and can be referenced from Chemical Appliation s of Group Theory
(2nd Editon) by F. Albert Cotton, Wiley-Interscience, 1971.
Pseudo-symmetry, such as a pseudo C.sub.2-axis of symmetry refers
to the same symmetry operation, however, the substituents on the
ligand frame do not need to be identical, but of similar size and
steric bulk. Substituents of similar size are typically within 4
atoms of each other, and of similar shape. For example, methyl,
ethyl, n-propyl, n-butyl and iso-butyl substituents (e.g. C1-C4
primary bonded substituents) would be considered of similar size
and steric bulk. Likewise, iso-propyl, sec-butyl, 1-methylbutyl,
1-ethylbutyl and 1-methylpentyl substituents (e.g. C3-C6 secondary
bonded substituents) would be considered of similar size and steric
bulk. Tert-butyl, 1,1-dimethylpropyl, 1,1-dimethylbutyl,
1,1-dimethylpentyl and 1-ethyl-1-methylpropyl (e.g. C4-C7 tertiary
bonded substituents) would be considered of similar size and steric
bulk. Phenyl, tolyl, xylyl, and mesityl substituents (C6-C9 aryl
substituents) would be considered of similar size and steric bulk.
Additionally, the bridging substituents of a compound with a pseudo
C.sub.2-axis of symmetry do not have to be similar at all since
they are far removed from the active site of the catalyst.
Therefore, a compound with a pseudo C.sub.2-axis of symmetry could
have for example, a Me.sub.2Si, MeEtSi or MePhSi bridging ligand,
and still be considered to have a pseudo C.sub.2-axis of symmetry
given the appropriate remaining ligand structure. In some
embodiments, metallocenes with a Claxis of symmetry may also be
useful herein.
[0132] For purposes of this disclosure, the term oligomer refers to
compositions having 2-75 mer units and the term polymer refers to
compositions having 76 or more mer units. A mer is defined as a
unit of an oligomer or polymer that originally corresponded to the
olefin(s) used in the oligomerization or polymerization reaction.
For example, the mer of polydecene would be decene.
[0133] The metallocene compounds (pre-catalysts), useful herein are
preferably cyclopentadienyl derivatives of titanium, zirconium and
hafnium. In general, useful titanocenes, zirconocenes and
hafnocenes may be represented by the following formulae:
(Cp-A'-Cp*)MX.sub.1X.sub.2 (1)
(CpCp*)MX.sub.1X.sub.2 (2)
wherein: M is the metal center, and is a Group 4 metal preferably
titanium, zirconium or hafnium, preferably zirconium or hafnium; Cp
and Cp* are the same or different cyclopentadienyl rings that are
each bonded to M, and substituted with from zero to four
substituent groups S'' for formula (1) and zero to five
substituents for formula (2), each substituent group S'' being,
independently, a radical group which is a hydrocarbyl, substituted
hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl or
germylcarbyl, or Cp and Cp* are the same or different
cyclopentadienyl rings in which any two adjacent S'' groups are
optionally joined to form a substituted or unsubstituted,
saturated, partially unsaturated, or aromatic cyclic or polycyclic
substituent; A' is a bridging group; X.sub.1 and X.sub.2 are,
independently, hydride radicals, hydrocarbyl radicals, substituted
hydrocarbyl radicals, halocarbyl radicals, substituted halocarbyl
radicals, silylcarbyl radicals, substituted silylcarbyl radicals,
germylcarbyl radicals, or substituted germylcarbyl radicals; or
both X are joined and bound to the metal atom to form a
metallacycle ring containing from about 3 to about 20 carbon atoms;
or both together can be an olefin, diolefin or aryne ligand; or
when Lewis-acid activators, such as methylalumoxane, which are
capable of donating an X ligand as described above to the
transition metal component are used, both X may, independently, be
a halogen, alkoxide, aryloxide, amide, phosphide or other univalent
anionic ligand or both X can also be joined to form a anionic
chelating ligand. In a preferred embodiment the metallocene is
racemic which means in a preferred embodiment, that the compounds
represented by formula (1) [(Cp-A'-Cp*)MX.sub.1X.sub.2] have no
plane of symmetry containing the metal center, M; and have a
C.sub.2-axis of symmetry or pseudo C.sub.2-axis of symmetry through
the metal center. Preferably in the racemic metallocenes
represented by formula (1) A' is selected from R'.sub.2C,
R'.sub.2Si, R'.sub.2Ge, R'.sub.2CCR'.sub.2,
R'.sub.2CCR'.sub.2CR'.sub.2, R'.sub.2CCR'.sub.2CR'.sub.2CR'.sub.2,
R'C.dbd.CR', R'C.dbd.CR'CR'.sub.2, R'.sub.2CCR'=CR'CR'.sub.2,
R'C.dbd.CR'CR'=CR', R'C.dbd.CR'CR'.sub.2CR'.sub.2,
R'.sub.2CSiR'.sub.2, R'.sub.2SiSiR'.sub.2,
R'.sub.2CSiR'.sub.2CR'.sub.2, R'.sub.2SiCR'.sub.2SiR'.sub.2,
R'C.dbd.CR'SiR'.sub.2, R'.sub.2CGeR'.sub.2, R'.sub.2GeGeR'.sub.2,
R'.sub.2CGeR'.sub.2CR'.sub.2, R'.sub.2GeCR'.sub.2GeR'.sub.2,
R'.sub.2SiGeR'.sub.2, R'C.dbd.CR'GeR'.sub.2, R'B, R'.sub.2C--BR',
R'.sub.2C--BR'--CR'.sub.2, R'N, R'P, O, S, Se,
R'.sub.2C--O--CR'.sub.2, R'.sub.2CR'.sub.2C--O--CR'.sub.2CR'.sub.2,
R'.sub.2C--O--CR'.sub.2CR'.sub.2, R'.sub.2C--O--CR'.dbd.CR',
R'.sub.2C--S--CR'.sub.2, R'.sub.2CR'.sub.2C--S--CR'.sub.2CR'.sub.2,
R'.sub.2C--S--CR'.sub.2CR'.sub.2, R'.sub.2C--S--CR'.dbd.CR',
R'.sub.2C--Se--CR'.sub.2,
R'.sub.2CR'.sub.2C--Se--CR'.sub.2CR'.sub.2,
R'.sub.2C--Se--CR'.sub.2CR'.sub.2, R'.sub.2C--Se--CR'.dbd.CR',
R'.sub.2C--N.dbd.CR', R'.sub.2C--NR'--CR'.sub.2,
R'.sub.2C--NR'--CR'.sub.2CR'.sub.2, R'.sub.2C--NR'--CR'.dbd.CR',
R'.sub.2CR'.sub.2C--NR'--CR'.sub.2CR'.sub.2, R'.sub.2C--P.dbd.CR',
and R'.sub.2C--PR'--CR'.sub.2 where when Cp is different than Cp*
then R' is a C.sub.105 containing hydrocarbyl, substituted
hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl or
germylcarbyl substituent, and when Cp is the same as Cp* then R' is
selected from hydrogen, C1-C20 containing hydrocarbyl, substituted
hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl or
germylcarbyl substituent and optionally two or more adjacent R' may
join to form a substituted or unsubstituted, saturated, partially
unsaturated, cyclic or polycyclic substituent.
[0134] Table A depicts representative constituent moieties for the
metallocene components of formula I and 2. The list is for
illustrative purposes only and should not be construed to be
limiting in any way. A number of final components may be formed by
permuting all possible combinations of the constituent moieties
with each other. When hydrocarbyl radicals including alkyl,
alkenyl, alkynyl, cycloalkyl, cycloalkenyl, cycloalkynyl and
aromatic radicals are disclosed in this application the term
includes all isomers. For example, butyl includes n-butyl,
2-methylpropyl, 1-methylpropyl, tert-butyl, and cyclobutyl; pentyl
includes n-pentyl, 1-methylbutyl, 2-methylbutyl, 3-methylbutyl,
1-ethylpropyl, neopentyl, cyclopentyl and methylcyclobutyl; butenyl
includes E and Z forms of 1-butenyl, 2-butenyl, 3-butenyl,
1-methyl-1-propenyl, 1-methyl-2-propenyl, 2-methyl-1-propenyl and
2-methyl-2-propenyl. This includes when a radical is bonded to
another group, for example, propylcyclopentadienyl include
n-propylcyclopentadienyl, isopropylcyclopentadienyl and
cyclopropylcyclopentadienyl. In general, the ligands or groups
illustrated in Table
A include all isomeric forms. For example, dimethylcyclopentadienyl
includes 1,2-dimethylcyclopentadienyl and
1,3-dimethylcyclopentadienyl; methylindenyl includes
1-methylindenyl, 2-methylindenyl, 3-methylindenyl, 4-methylindenyl,
5-methylindenyl, 6-methylindenyl and 7-methylindenyl;
methylethylphenyl includes ortho-methylethylphenyl,
meta-methylethylphenyl and para-methylethylphenyl. Examples of
specific invention catalyst precursors take the following formula
where some components are listed in Table A. To illustrate members
of the transition metal component, select any combination of the
species listed in Tables A. For nomenclature purposes, for the
bridging group, A', the words "silyl" and "silylene" are used
interchangeably, and represent a diradical species. For the
bridging group A', "ethylene" refers to a 1,2-ethylene linkage and
is distinguished from ethene-1,1-diyl. Thus, for the bridging group
A', "ethylene" and "1,2-ethylene" are used interchangeably. For
compounds having a bridging group, A', the bridge position on the
cyclopentadienyl-type ring is always considered the 1-position. The
numbering scheme previous defined for the indenyl ring is used to
indicate the bridge position; if a number is not specified, it is
assumed that the bridge to the indenyl ligand is in the one
position.
TABLE-US-00002 TABLE A A' dimethylsilylene diethylsilylene
dipropylsilylene dibutylsilylene dipentylsilylene dihexylsilylene
diheptylsilylene dioctylsilylene dinonylsilylene didecylsilylene
diundecylsilylene didodecylsilylene ditridecylsilylene
ditetradecylsilylene dipentadecylsilylene dihexadecylsilylene
diheptadecylsilylene dioctadecylsilylene dinonadecylsilylene
dieicosylsilylene diheneicosylsilylene didocosylsilylene
ditricosylsilylene ditetracosylsilylene dipentacosylsilylene
dihexacosylsilylene diheptacosylsilylene dioctacosylsilylene
dinonacosylsilylene ditriacontylsilylene dicyclohexylsilylene
dicyclopentylsilylene dicycloheptylsilylene dicyclooctylsilylene
dicyclodecylsilylene dicyclododecylsilylene dinapthylsilylene
diphenylsilylene ditolylsilylene dibenzylsilylene
diphenethylsilylene di(butylphenethyl)silylene methylethylsilylene
methylpropylsilylene methylbutylsilylene methylhexylsilylene
methylphenylsilylene ethylphenylsilylene ethylpropylsilylene
ethylbutylsilylene propylphenylsilylene dimethylgermylene
diethylgermylene diphenylgermylene methylphenylgermylene
cyclotetramethylenesilylene cyclopentamethylenesilylene
cyclotrimethylenesilylene cyclohexylazanediyl butylazanediyl
methylazanediyl phenylazanediyl perfluorophenylazanediyl
methylphosphanediyl ethylphosphanediyl propylphosphanediyl
butylphosphanediyl cyclohexylphosphanediyl phenylphosphanediyl
methylboranediyl phenylboranediyl methylene dimethylmethylene
diethylmethylene dibutylmethylene dipropylmethylene
diphenylmethylene ditolylmethylene di(butylphenyl)methylene
di(trimethylsilylphenyl)methylene di(triethylsilylphenyl)methylene
dibenzylmethylene cyclotetramethylenemethylene
cyclopentamethylenemethylene ethylene methylethylene
dimethylethylene trimethylethylene tetramethylethylene
cyclopentylene cyclohexylene cycloheptylene cyclooctylene
propanediyl methylpropanediyl dimethylpropanediyl
trimethylpropanediyl tetramethylpropanediyl pentamethylpropanediyl
hexamethylpropanediyl tetramethyldisiloxylene vinylene
ethene-1,1-diyl divinylsilylene dipropenylsilylene
dibutenylsilylene methylvinylsilylene methylpropenylsilylene
methylbutenylsilylene dimethylsilylmethylene diphenylsilylmethylene
dimethylsilylethylene diphenylsilylethylene dimethylsilylpropylene
diphenylsilylpropylene dimethylstannylene diphenylstannylene
X.sub.1 or X.sub.2 chloride bromide iodide fluoride hydride methyl
ethyl propyl butyl pentyl hexyl heptyl octyl nonyl decyl undecyl
dodecyl tridecyl tetradecyl pentadecyl hexadecyl heptadecyl
octadecyl nonadecyl eicosyl heneicosyl docosyl tricosyl tetracosyl
pentacosyl hexacosyl heptacosyl octacosyl nonacosyl triacontyl
phenyl benzyl phenethyl tolyl methoxy ethoxy propoxy butoxy
dimethylamido diethylamido methylethylamido phenoxy benzoxy allyl
X.sub.1 and X.sub.2 together methylidene ethylidene propylidene
tetramethylene pentamethylene hexamethylene ethylenedihydroxy
butadiene methylbutadiene dimethylbutadiene pentadiene
methylpentadiene dimethylpentadiene hexadiene methylhexadiene
dimethylhexadiene M titanium zirconium hafnium Cp, Cp*
cyclopentadienyl methylcyclopentadienyl dimethylcyclopentadienyl
trimethylcyclopentadienyl tetramethylcyclopentadienyl
ethylcyclopentadienyl diethylcyclopentadienyl
propylcyclopentadienyl dipropylcyclopentadienyl
butylcyclopentadienyl dibutylcyclopentadienyl
pentylcyclopentadienyl dipentylcyclopentadienyl
hexylcyclopentadienyl dihexylcyclopentadienyl
heptylcyclopentadienyl diheptylcyclopentadienyl
octylcyclopentadienyl dioctylcyclopentadienyl nonylcyclopentadienyl
dinonylcyclopentadienyl decylcyclopentadienyl
didecylcyclopentadienyl undecylcyclopentadienyl
dodecylcyclopentadienyl tridecylcyclopentadienyl
tetradecylcyclopentadienyl pentadecylcyclopentadienyl
hexadecylcyclopentadienyl heptadecylcyclopentadienyl
octadecylcyclopentadienyl nonadecylcyclopentadienyl
eicosylcyclopentadienyl heneicosylcyclopentadienyl
docosylcyclopentadienyl tricosylcyclopentadienyl
tetracosylcyclopentadienyl pentacosylcyclopentadienyl
hexacosylcyclopentadienyl heptacosylcyclopentadienyl
octacosylcyclopentadienyl nonacosylcyclopentadienyl
triacontylcyclopentadienyl cyclohexylcyclopentadienyl
phenylcyclopentadienyl diphenylcyclopentadienyl
triphenylcyclopentadienyl tetraphenylcyclopentadienyl
tolylcyclopentadineyl benzylcyclopentadienyl
phenethylcyclopentadienyl cyclohexylmethylcyclopentadienyl
napthylcyclopentadienyl methylphenylcyclopentadienyl
methyltolylcyclopentadienyl methylethylcyclopentadienyl
methylpropylcyclopentadienyl methylbutylcyclopentadienyl
methylpentylcyclopentadienyl methylhexylcyclopentadienyl
methylheptylcyclpentadienyl methyloctylcyclopentadienyl
methylnonylcyclopentadienyl methyldecylcyclopentadienyl
vinylcyclopentadienyl propenylcyclopentadienyl
butenylcyclopentadienyl indenyl methylindenyl dimethylindenyl
trimethylindenyl tetramethylindenyl pentamethylindenyl
methylpropylindenyl dimethylpropylindenyl methyldipropylindenyl
methylethylindenyl methylbutylindenyl ethylindenyl propylindenyl
butylindenyl pentylindenyl hexylindenyl heptylindenyl octylindenyl
nonylindenyl decylindenyl phenylindenyl (fluorophenyl)indenyl
(methylphenyl)indenyl biphenylindenyl
(bis(trifluoromethyl)phenyl)indenyl napthylindenyl
phenanthrylindenyl benzylindenyl benzindenyl cyclohexylindenyl
methylphenylindenyl ethylphenylindenyl propylphenylindenyl
methylnapthylindenyl ethylnapthylindenyl propylnapthylindenyl
(methylphenyl)indenyl (dimethylphenyl)indenyl (ethylphenyl)indenyl
(diethylphenyl)indenyl (propylphenyl)indenyl
(dipropylphenyl)indenyl methyltetrahydroindenyl
ethyltetrahydroindenyl propyltetrahydroindenyl
butyltetrahydroindenyl phenyltetrahydroindenyl
(diphenylmethyl)cyclopentadienyl trimethylsilylcyclopentadienyl
triethylsilylcyclopentadienyl trimethylgermylcyclopentadienyl
trifluromethylcyclopentadienyl cyclopenta[b]thienyl
cyclopenta[b]furanyl cyclopenta[b]selenophenyl
cyclopenta[b]tellurophenyl cyclopenta[b]pyrrolyl
cyclopenta[b]phospholyl cyclopenta[b]arsolyl cyclopenta[b]stibolyl
methylcyclopenta[b]thienyl methylcyclopenta[b]furanyl
methylcyclopenta[b]selenophenyl methylcyclopenta[b]tellurophenyl
methylcyclopenta[b]pyrrolyl methylcyclopenta[b]phospholyl
methylcyclopenta[b]arsolyl methylcyclopenta[b]stibolyl
dimethylcyclopenta[b]thienyl dimethylcyclopenta[b]furanyl
dimethylcyclopenta[b]pyrrolyl dimethylcyclopenta[b]phospholyl
trimethylcyclopenta[b]thienyl trimethylcyclopenta[b]furanyl
trimethylcyclopenta[b]pyrrolyl trimethylcyclopenta[b]phospholyl
ethylcyclopenta[b]thienyl ethylcyclopenta[b]furanyl
ethylcyclopenta[b]pyrrolyl ethylcyclopenta[b]phospholyl
diethylcyclopenta[b]thienyl diethylcyclopenta[b]furanyl
diethylcyclopenta[b]pyrrolyl diethylcyclopenta[b]phospholyl
triethylcyclopenta[b]thienyl triethylcyclopenta[b]furanyl
triethylcyclopenta[b]pyrrolyl triethylcyclopenta[b]phospholyl
propylcyclopenta[b]thienyl propylcyclopenta[b]furanyl
propylcyclopenta[b]pyrrolyl propylcyclopenta[b]phospholyl
dipropylcyclopenta[b]thienyl dipropylcyclopenta[b]furanyl
dipropylcyclopenta[b]pyrrolyl dipropylcyclopenta[b]phospholyl
tripropylcyclopenta[b]thienyl tripropylcyclopenta[b]furanyl
tripropylcyclopenta[b]pyrrolyl tripropylcyclopenta[b]phospholyl
butylcyclopenta[b]thienyl butylcyclopenta[b]furanyl
butylcyclopenta[b]pyrrolyl butylcyclopenta[b]phospholyl
dibutylcyclopenta[b]thienyl dibutylcyclopenta[b]furanyl
dibutylcyclopenta[b]pyrrolyl dibutylcyclopenta[b]phospholyl
tributylcyclopenta[b]thienyl tributylcyclopenta[b]furanyl
tributylcyclopenta[b]pyrrolyl tributylcyclopenta[b]phospholyl
ethylmethylcyclopenta[b]thienyl ethylmethylcyclopenta[b]furanyl
ethylmethylcyclopenta[b]pyrrolyl ethylmethylcyclopenta[b]phospholyl
methylpropylcyclopenta[b]thienyl methylpropylcyclopenta[b]furanyl
methylpropylcyclopenta[b]pyrrolyl
methylpropylcyclopenta[b]phospholyl butylmethylcyclopenta[b]thienyl
butylmethylcyclopenta[b]furanyl butylmethylcyclopenta[b]pyrrolyl
butylmethylcyclopenta[b]phospholyl cyclopenta[c]thienyl
cyclopenta[c]furanyl cyclopenta[c]selenophenyl
cyclopenta[c]tellurophenyl cyclopenta[c]pyrrolyl
cyclopenta[c]phospholyl cyclopenta[c]arsolyl cyclopenta[c]stibolyl
methylcyclopenta[c]thienyl methylcyclopenta[c]furanyl
methylcyclopenta[c]selenophenyl methylcyclopenta[c]tellurophenyl
methylcyclopenta[c]pyrrolyl methylcyclopenta[c]phospholyl
methylcyclopenta[c]arsolyl methylcyclopenta[c]stibolyl
dimethylcyclopenta[c]thienyl dimethylcyclopenta[c]furanyl
dimethylcyclopenta[c]pyrrolyl dimethylcyclopenta[c]phospholyl
trimethylcyclopenta[c]thienyl trimethylcyclopenta[c]furanyl
trimethylcyclopenta[c]pyrrolyl trimethylcyclopenta[c]phospholyl
ethylcyclopenta[c]thienyl ethylcyclopenta[c]furanyl
ethylcyclopenta[c]pyrrolyl ethylcyclopenta[c]phospholyl
diethylcyclopenta[c]thienyl diethylcyclopenta[c]furanyl
diethylcyclopenta[c]pyrrolyl diethylcyclopenta[c]phospholyl
triethylcyclopenta[c]thienyl triethylcyclopenta[c]furanyl
triethylcyclopenta[c]pyrrolyl triethylcyclopenta[c]phospholyl
propylcyclopenta[c]thienyl propylcyclopenta[c]furanyl
propylcyclopenta[c]pyrrolyl propylcyclopenta[c]phospholyl
dipropylcyclopenta[c]thienyl dipropylcyclopenta[c]furanyl
dipropylcyclopenta[c]pyrrolyl dipropylcyclopenta[c]phospholyl
tripropylcyclopenta[c]thienyl tripropylcyclopenta[c]furanyl
tripropylcyclopenta[c]pyrrolyl tripropylcyclopenta[c]phospholyl
butylcyclopenta[c]thienyl butylcyclopenta[c]furanyl
butylcyclopenta[c]pyrrolyl butylcyclopenta[c]phospholyl
dibutylcyclopenta[c]thienyl dibutylcyclopenta[c]furanyl
dibutylcyclopenta[c]pyrrolyl dibutylcyclopenta[c]phospholyl
tributylcyclopenta[c]thienyl tributylcyclopenta[c]furanyl
tributylcyclopenta[c]pyrrolyl tributylcyclopenta[c]phospholyl
ethylmethylcyclopenta[c]thienyl ethylmethylcyclopenta[c]furanyl
ethylmethylcyclopenta[c]pyrrolyl ethylmethylcyclopenta[c]phospholyl
methylpropylcyclopenta[c]thienyl methylpropylcyclopenta[c]furanyl
methylpropylcyclopenta[c]pyrrolyl
methylpropylcyclopenta[c]phospholyl butylmethylcyclopenta[c]thienyl
butylmethylcyclopenta[c]furanyl butylmethylcyclopenta[c]pyrrolyl
butylmethylcyclopenta[c]phospholyl pentamethylcyclopentadienyl
tetrahydroindenyl mehtyltetrahydroindenyl
dimethyltetrahydroindenyl
[0135] In a preferred embodiment of the invention, Cp is the same
as Cp* and is a substituted or unsubstituted indenyl or
tetrahydroindenyl ligand. Most preferred substituted indenyl or
tetrahydroindenyl ligands do not have a substituent in the
2-position of the indenyl or tetrahydroindenyl ring. Most preferred
substituted and unsubstituted indenyl or tetrahydroindenyl ligands
include indenyl, tetrahydroindenyl, 4,7-dimethylindenyl and
5,6-dimethylindenyl.
[0136] In another embodiment, the metallocene catalyst compound
used herein is not rac-CH.sub.2CH.sub.2(Ind).sub.2ZrCl.sub.2 and or
rac-Me.sub.2Si(2-Me-Ind).sub.2ZrCl.sub.2. In another embodiment,
the metallocene catalyst compound used herein is not
rac-CH.sub.2CH.sub.2(Ind).sub.2ZrCl.sub.2 and or
rac-Me.sub.2Si(2-Me-Ind).sub.2ZrCl.sub.2 and the activator is not
methylalumoxane, where Me is methyl and Ind is indenyl.
[0137] In a preferred embodiment of the invention, when the
metallocene is used with an alumoxane, Cp is the same as Cp* and is
a substituted or unsubstituted indenyl or tetrahydroindenyl ligand.
Most preferred substituted indenyl or tetrahydroindenyl ligands do
not have a substituent in the 2-position of the indenyl or
tetrahydroindenyl ring. Most preferred substituted and
unsubstituted indenyl or tetrahydroindenyl ligands include indenyl,
tetrahydroindenyl, 4,7-dimethylindenyl and 5,6-dimethylindenyl.
[0138] In another embodiment, when the metallocene is used with an
alumoxane, then the metallocene catalyst compound used herein is
not rac-CH.sub.2CH.sub.2(Ind).sub.2ZrCl.sub.2 and or
rac-Me.sub.2Si(2-Me-Ind).sub.2ZrCl.sub.2. In another embodiment,
the metallocene catalyst compound used herein is not
rac-CH.sub.2CH.sub.2(Ind).sub.2ZrCl.sub.2 and or
rac-Me.sub.2Si(2-Me-Ind).sub.2ZrCl.sub.2 and the activator is not
methylalumoxane, where Me is methyl and Ind is indenyl.
[0139] In a preferred embodiment of the invention, when used with
an NCA, Cp is the same as Cp* and is a substituted or unsubstituted
indenyl or tetrahydroindenyl ligand. Most preferred substituted and
unsubstituted indenyl or tetrahydroindenyl ligands include having a
substituent in the 2-position of the indenyl or tetrahydroindenyl
ring, indenyl, tetrahydroindenyl, 4,7-dimethylindenyl and
5,6-dimethylindenyl.
[0140] In another embodiment, when used with NCA, the metallocene
catalyst compound used herein is bridged, substituted or
unsubstituted metallocenes of general structure as shown in formula
(1) or (2)
[0141] In another embodiment, the catalyst used herein is
Y.sub.2methylidene(R.sub.nCp)(R.sub.mFlu)ZrX.sub.2 or
Y.sub.2silyl(R.sub.nCp)(R.sub.mFlu)ZrX.sub.2 where Y is
independently a C.sub.1 to C.sub.20 alkyl or a substituted or
unsubstituted phenyl group, X is a halogen, a substituted or
unsubstituted phenyl group, or a C.sub.1 to C.sub.20 alkyl, Cp is a
cyclopentadienyl ring, R is a C.sub.1 to C.sub.20 alkyl group, n is
a number denoting the degree of substitution of Cp and is a number
from 0 to 5, Flu is a fluorenyl ring, m is a number denoting the
degree of substitution of Flu and is a number from 0 to 9.
[0142] Preferred metallocene compounds (pre-catalysts) which,
according to the present invention, provide catalyst systems which
are specific to the production of poly-.alpha.-olefins having mm
triads over 40% include the racemic versions of:
dimethylsilylbis(indenyl) zirconium dichloride,
dimethylsilylbis(indenyl) zirconium dimethyl,
diphenylsilylbis(indenyl) zirconium dichloride,
diphenylsilylbis(indenyl) zirconium dimethyl,
methylphenylsilylbis(indenyl) zirconium dichloride,
methylphenylsilylbis(indenyl) zirconium dimethyl,
ethylenebis(indenyl) zirconium dichloride, ethylenebis(indenyl)
zirconium dimethyl, methylenebis(indenyl) zirconium dichloride,
methylenebis(indenyl) zirconium dimethyl, dimethylsilylbis(indenyl)
hafnium dichloride, dimethylsilylbis(indenyl) hafnium dimethyl,
diphenylsilylbis(indenyl) hafnium dichloride,
diphenylsilylbis(indenyl) hafnium dimethyl,
methylphenylsilylbis(indenyl) hafnium dichloride,
methylphenylsilylbis(indenyl) hafnium dimethyl,
ethylenebis(indenyl) hafnium dichloride, ethylenebis(indenyl)
hafnium dimethyl, methylenebis(indenyl) hafnium dichloride,
methylenebis(indenyl) hafnium dimethyl,
dimethylsilylbis(tetrahydroindenyl) zirconium dichloride,
dimethylsilylbis(tetrahydroindenyl) zirconium dimethyl,
diphenylsilylbis(tetrahydroindenyl) zirconium dichloride,
diphenylsilylbis(tetrahydroindenyl) zirconium dimethyl,
methylphenylsilylbis(tetrahydroindenyl) zirconium dichloride,
methylphenylsilylbis(tetrahydroindenyl) zirconium dimethyl,
ethylenebis(tetrahydroindenyl) zirconium dichloride,
ethylenebis(tetrahydroindenyl) zirconium dimethyl,
methylenebis(tetrahydroindenyl) zirconium dichloride,
methylenebis(tetrahydroindenyl) zirconium dimethyl,
dimethylsilylbis(tetrahydroindenyl) hafnium dichloride,
dimethylsilylbis(tetrahydroindenyl) hafnium dimethyl,
diphenylsilylbis(tetrahydroindenyl) hafnium dichloride,
diphenylsilylbis(tetrahydroindenyl) hafnium dimethyl,
methylphenylsilylbis(tetrahydroindenyl) hafnium dichloride,
methylphenylsilylbis(tetrahydroindenyl) hafnium dimethyl,
ethylenebis(tetrahydroindenyl) hafnium dichloride,
ethylenebis(tetrahydroindenyl) hafnium dimethyl,
methylenebis(tetrahydroindenyl) hafnium dichloride,
methylenebis(tetrahydroindenyl) hafnium dimethyl,
dimethylsilylbis(4,7-dimethylindenyl) zirconium dichloride,
dimethylsilylbis(4,7-dimethylindenyl) zirconium dimethyl,
diphenylsilylbis(4,7-dimethylindenyl) zirconium dichloride,
diphenylsilylbis(4,7-dimethylindenyl) zirconium dimethyl,
methylphenylsilylbis(4,7-dimethylindenyl) zirconium dichloride,
methylphenylsilylbis(4,7-dimethylindenyl) zirconium dimethyl,
ethylenebis(4,7-dimethylindenyl) zirconium dichloride,
ethylenebis(4,7-dimethylindenyl) zirconium dimethyl,
methylenebis(4,7-dimethylindenyl) zirconium dichloride,
methylenebis(4,7-dimethylindenyl) zirconium dimethyl,
dimethylsilylbis(4,7-dimethylindenyl) hafnium dichloride,
dimethylsilylbis(4,7-dimethylindenyl) hafnium dimethyl,
diphenylsilylbis(4,7-dimethylindenyl) hafnium dichloride,
diphenylsilylbis(4,7-dimethylindenyl) hafnium dimethyl,
methylphenylsilylbis(4,7-dimethylindenyl) hafnium dichloride,
methylphenylsilylbis(4,7-dimethylindenyl) hafnium dimethyl,
ethylenebis(4,7-dimethylindenyl) hafnium dichloride,
ethylenebis(4,7-dimethylindenyl) hafnium dimethyl,
methylenebis(4,7-dimethylindenyl) hafnium dichloride,
methylenebis(4,7-dimethylindenyl) hafnium dimethyl,
dimethylsilylbis(2-methyl-4-napthylindenyl) zirconium dichloride,
dimethylsilylbis(2-methyl-4-napthylindenyl) zirconium dimethyl,
diphenylsilylbis(2-methyl-4-napthylindenyl) zirconium dichloride,
dimethylsilylbis(2,3-dimethylcyclopentadienyl) zirconium
dichloride, dimethylsilylbis(2,3-dimethylcyclopentadienyl)
zirconium dimethyl, diphenylsilylbis(2,3-dimethylcyclopentadienyl)
zirconium dichloride,
diphenylsilylbis(2,3-dimethylcyclopentadienyl) zirconium dimethyl,
methylphenylsilylbis(2,3-dimethylcyclopentadienyl) zirconium
dichloride, methylphenylsilylbis(2,3-dimethylcyclopentadienyl)
zirconium dimethyl, ethylenebis(2,3-dimethylcyclopentadienyl)
zirconium dichloride, ethylenebis(2,3-dimethylcyclopentadienyl)
zirconium dimethyl, methylenebis(2,3-dimethylcyclopentadienyl)
zirconium dichloride, methylenebis(2,3-dimethylcyclopentadienyl)
zirconium dimethyl, dimethylsilylbis(2,3-dimethylcyclopentadienyl)
hafnium dichloride, dimethylsilylbis(2,3-dimethylcyclopentadienyl)
hafnium dimethyl, diphenylsilylbis(2,3-dimethylcyclopentadienyl)
hafnium dichloride, diphenylsilylbis(2,3-dimethylcyclopentadienyl)
hafnium dimethyl,
methylphenylsilylbis(2,3-dimethylcyclopentadienyl) hafnium
dichloride, methylphenylsilylbis(2,3-dimethylcyclopentadienyl)
hafnium dimethyl, ethylenebis(2,3-dimethylcyclopentadienyl) hafnium
dichloride, ethylenebis(2,3-dimethylcyclopentadienyl) hafnium
dimethyl, methylenebis(2,3-dimethylcyclopentadienyl) hafnium
dichloride, methylenebis(2,3-dimethylcyclopentadienyl) hafnium
dimethyl, dimethylsilylbis(3-trimethylsilylcyclopentadienyl)
zirconium dichloride,
dimethylsilylbis(3-trimethylsilylcyclopentadienyl) zirconium
dimethyl, diphenylsilylbis(3-trimethylsilylcyclopentadienyl)
zirconium dichloride,
diphenylsilylbis(3-trimethylsilylcyclopentadienyl) zirconium
dimethyl, methylphenylsilylbis(3-trimethylsilylcyclopentadienyl)
zirconium dichloride,
methylphenylsilylbis(3-trimethylsilylcyclopentadienyl) zirconium
dimethyl, ethylenebis(3-trimethylsilylcyclopentadienyl) zirconium
dichloride, ethylenebis(3-trimethylsilylcyclopentadienyl) zirconium
dimethyl, methylenebis(3-trimethylsilylcyclopentadienyl) zirconium
dichloride, methylenebis(3-trimethylsilylcyclopentadienyl)
zirconium dimethyl,
dimethylsilylbis(3-trimethylsilylcyclopentadienyl) hafnium
dichloride, dimethylsilylbis(3-trimethylsilylcyclopentadienyl)
hafnium dimethyl,
diphenylsilylbis(3-trimethylsilylcyclopentadienyl) hafnium
dichloride, diphenylsilylbis(3-trimethylsilylcyclopentadienyl)
hafnium dimethyl,
methylphenylsilylbis(3-trimethylsilylcyclopentadienyl) hafnium
dichloride, methylphenylsilylbis(3-trimethylsilylcyclopentadienyl)
hafnium dimethyl, ethylenebis(3-trimethylsilylcyclopentadienyl)
hafnium dichloride, ethylenebis(3-trimethylsilylcyclopentadienyl)
hafnium dimethyl, methylenebis(3-trimethylsilylcyclopentadienyl)
hafnium dichloride, methylenebis(3-trimethylsilylcyclopentadienyl)
hafnium dimethyl,
[0143] Particularly preferred species are the racemic versions of:
dimethylsilylbis(indenyl) zirconium dichloride,
dimethylsilylbis(indenyl) zirconium dimethyl, ethylenebis(indenyl)
zirconium dichloride, ethylenebis(indenyl) zirconium dimethyl,
dimethylsilylbis(tetrahydroindenyl) zirconium dichloride,
dimethylsilylbis(tetrahydroindenyl) zirconium dimethyl,
ethylenebis(tetrahydroindenyl) zirconium dichloride,
ethylenebis(tetrahydroindenyl) zirconium dimethyl,
dimethylsilylbis(4,7-dimethylindenyl) zirconium dichloride,
dimethylsilylbis(4,7-dimethylindenyl) zirconium dimethyl,
ethylenebis(4,7-dimethylindenyl) zirconium dichloride,
ethylenebis(4,7-dimethylindenyl) zirconium dimethyl,
dimethylsilylbis(indenyl) hafnium dichloride,
dimethylsilylbis(indenyl) hafnium dimethyl, ethylenebis(indenyl)
hafnium dichloride, ethylenebis(indenyl) hafnium dimethyl,
dimethylsilylbis(tetrahydroindenyl) hafnium dichloride,
dimethylsilylbis(tetrahydroindenyl) hafnium dimethyl,
ethylenebis(tetrahydroindenyl) hafnium dichloride,
ethylenebis(tetrahydroindenyl) hafnium dimethyl,
dimethylsilylbis(4,7-dimethylindenyl) hafnium dichloride,
dimethylsilylbis(4,7-dimethylindenyl) hafnium dimethyl,
ethylenebis(4,7-dimethylindenyl) hafnium dichloride, and
ethylenebis(4,7-dimethylindenyl) hafnium dimethyl.
[0144] Preferred catalyst compounds also include
bis(1,3-dimethylcyclopentadienyl)zirconium dichloride and
bis(tetramethylcyclopentadienyl)zirconium dichloride
Activators and Catalyst Activation
[0145] The catalyst precursors, when activated by a commonly known
activator such as methylalumoxane, form active catalysts for the
polymerization or oligomerization of olefins. Activators that may
be used include alumoxanes such as methylalumoxane, modified
methylalumoxane, ethylalumoxane, iso-butylalumoxane and the like;
Lewis acid activators include triphenylboron,
tris-perfluorophenylboron, tris-perfluorophenylaluminum and the
like; ionic activators include dimethylanilinium
tetrakisperfluorophenylborate, triphenylcarboniumtetrakis
perfluorophenylborate,
dimethylaniliniumtetrakisperfluorophenylaluminate, and the
like.
[0146] A co-activator is a compound capable of alkylating the
transition metal complex, such that when used in combination with
an activator, an active catalyst is formed. Co-activators include
alumoxanes such as methylalumoxane, modified alumoxanes such as
modified methylalumoxane, and aluminum alkyls such
trimethylaluminum, tri-isobutylaluminum, triethylaluminum, and
tri-isopropylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum,
tri-n-decylaluminum or tri-n-dodecylaluminum. Co-activators are
typically used in combination with Lewis acid activators and ionic
activators when the pre-catalyst is not a dihydrocarbyl or
dihydride complex. Sometimes co-activators are also used as
scavengers to deactivate impurities in feed or reactors.
[0147] Particularly preferred co-activators include alkylaluminum
compound is represented by the formula: R.sub.3Al, where each R is,
independently, a C.sub.1 to C.sub.18 alkyl group, preferably each R
is, independently, selected from the group consisting of methyl,
ethyle, n-propyl, iso-propyl, iso-butyl, n-butyl, t-butyl,
n-pentyl, iso-pentyl, neopentyl, n-hexyl, iso-hexyl, n-heptyl,
iso-heptyl, n-octyl, iso-octyl, n-nonyl, n-decyl, n-undecyl,
n-dodecyl, n-tridecyl, n-tetradecyl, n-pentadecy, n-hexadecyl,
n-heptadecyl, n-octadecyl, and their iso-analogs.
[0148] The alumoxane component useful as an activator typically is
preferably an oligomeric aluminum compound represented by the
general formula (R.sup.x--Al--O).sub.n, which is a cyclic compound,
or R.sup.x(R.sup.x--Al--O).sub.nAlR.sup.x.sub.2, which is a linear
compound. It is believed that the most common alumoxanes are a
mixture of the cyclic and linear compounds. In the general
alumoxane formula, R.sup.x is independently a C.sub.1-C.sub.20
alkyl radical, for example, methyl, ethyl, propyl, butyl, pentyl,
isomers thereof, and the like, and "n" is an integer from 1-50.
Most preferably, IV is methyl and "n" is at least 4.
Methylalumoxane and modified methylalumoxanes are most preferred.
For further descriptions see, EP 0 279 586, EP 0 594 218, EP 0 561
476, WO94/10180 and U.S. Pat. Nos. 4,665,208, 4,874,734, 4,908,463,
4,924,018, 4,952,540, 4,968,827, 5,041,584, 5,091,352, 5,103,031,
5,157,137, 5,204,419, 5,206,199, 5,235,081, 5,248,801, 5,329,032,
5,391,793, and 5,416,229.
[0149] When an alumoxane or modified alumoxane is used, the
catalyst-precursor-to-activator molar ratio is from about 1:3000 to
10:1; alternatively, 1:2000 to 10:1; alternatively 1:1000 to 10:1;
alternatively, 1:500 to 1:1; alternatively 1:300 to 1:1;
alternatively 1:250 to 1:1, alternatively 1:200 to 1:1;
alternatively 1:100 to 1:1; alternatively 1:50 to 1:1;
alternatively 1:10 to 1:1. When the activator is an alumoxane
(modified or unmodified), some embodiments select the maximum
amount of activator at a 5000-fold molar excess over the catalyst
precursor (per metal catalytic site). The preferred minimum
activator-to-catalyst-precursor ratio is 1:1 molar ratio.
[0150] Ionic activators (at times used in combination with a
co-activator) may be used in the practice of this invention.
Preferably, discrete ionic activators such as
[Me.sub.2PhNH][B(C.sub.6F.sub.5).sub.4],
[Ph.sub.3C][B(C.sub.6F.sub.5).sub.4],
[Me.sub.2PhNH][B((C.sub.6H.sub.3-3,5-(CF.sub.3).sub.2)).sub.4],
[Ph.sub.3C][B((C.sub.6H.sub.3-3,5-(CF.sub.3).sub.2)).sub.4],
[NH.sub.4][B(C.sub.6H.sub.5).sub.4] or Lewis acidic activators such
as B(C.sub.6F.sub.5).sub.3 or B(C.sub.6H.sub.5).sub.3 can be used,
where Ph is phenyl and Me is methyl. Preferred co-activators, when
used, are alumoxanes such as methylalumoxane, modified alumoxanes
such as modified methylalumoxane, and aluminum alkyls such as
tri-isobutylaluminum, and trimethylaluminum, triethylaluminum, and
tri-isopropylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum,
tri-n-decylaluminum or tri-n-dodecylaluminum.
[0151] It is within the scope of this invention to use an ionizing
or stoichiometric activator, neutral or ionic, such as
tri(n-butyl)ammoniumtetrakis(pentafluorophenyl) borate, a
trisperfluorophenyl boron metalloid precursor or a
trisperfluoronaphthyl boron metalloid precursor, polyhalogenated
heteroborane anions (WO 98/43983), boric acid (U.S. Pat. No.
5,942,459) or combination thereof.
[0152] Examples of neutral stoichiometric activators include
tri-substituted boron, tellurium, aluminum, gallium and indium or
mixtures thereof. The three substituent groups are each
independently selected from alkyls, alkenyls, halogen, substituted
alkyls, aryls, arylhalides, alkoxy and halides. Preferably, the
three groups are independently selected from halogen, mono or
multicyclic (including halosubstituted) aryls, alkyls, and alkenyl
compounds and mixtures thereof, preferred are alkenyl groups having
1 to 20 carbon atoms, alkyl groups having 1 to 20 carbon atoms,
alkoxy groups having 1 to 20 carbon atoms and aryl groups having 3
to 20 carbon atoms (including substituted aryls). More preferably,
the three groups are alkyls having 1 to 4 carbon groups, phenyl,
naphthyl or mixtures thereof. Even more preferably, the three
groups are halogenated, preferably fluorinated, aryl groups. Most
preferably, the neutral stoichiometric activator is
trisperfluorophenyl boron or trisperfluoronaphthyl boron.
[0153] Ionic stoichiometric activator compounds may contain an
active proton, or some other cation associated with, but not
coordinated to, or only loosely coordinated to, the remaining ion
of the ionizing compound. Such compounds and the like are described
in European publications EP-A-0 570 982, EP-A-0 520 732, EP-A-0 495
375, EP-B1-0 500 944, EP-A-0 277 003 and EP-A-0 277 004, and U.S.
Pat. Nos. 5,153,157, 5,198,401, 5,066,741, 5,206,197, 5,241,025,
5,384,299 and 5,502,124 and U.S. patent application Ser. No.
08/285,380, filed Aug. 3, 1994, all of which are herein fully
incorporated by reference.
[0154] Ionic catalysts can be prepared by reacting a transition
metal compound with an activator, such as B(C.sub.6F.sub.6).sub.3,
which upon reaction with the hydrolyzable ligand (X') of the
transition metal compound forms an anion, such as
([B(C.sub.6F.sub.5).sub.3(X')].sup.-), which stabilizes the
cationic transition metal species generated by the reaction. The
catalysts can be, and preferably are, prepared with activator
components which are ionic compounds or compositions. However
preparation of activators utilizing neutral compounds is also
contemplated by this invention.
[0155] Compounds useful as an activator component in the
preparation of the ionic catalyst systems used in the process of
this invention comprise a cation, which is preferably a Bronsted
acid capable of donating a proton, and a compatible
non-coordinating anion which anion is relatively large (bulky),
capable of stabilizing the active catalyst species which is formed
when the two compounds are combined and said anion will be
sufficiently labile to be displaced by olefinic diolefinic and
acetylenically unsaturated substrates or other neutral Lewis bases
such as ethers, nitriles and the like. Two classes of compatible
non-coordinating anions have been disclosed in EPA 277,003 and EPA
277,004 published 1988: 1) anionic coordination complexes
comprising a plurality of lipophilic radicals covalently
coordinated to and shielding a central charge-bearing metal or
metalloid core, and 2) anions comprising a plurality of boron atoms
such as carboranes, metallacarboranes and boranes. In a preferred
embodiment, the stoichiometric activators include a cation and an
anion component, and may be represented by the following
formula:(L**-H).sub.d.sup.+(A.sup.d-) wherein L** is an neutral
Lewis base; H is hydrogen; (L**-H).sup.+ is a Bronsted acidA.sup.d-
is a non-coordinating anion having the charge d-d is an integer
from 1 to 3.
[0156] The cation component, (L**-H).sub.d.sup.+ may include
Bronsted acids such as protons or protonated Lewis bases or
reducible Lewis acids capable of protonating or abstracting a
moiety, such as an alkyl or aryl, from the precatalyst after
alkylation.
[0157] The activating cation (L**-H).sub.d.sup.+ may be a Bronsted
acid, capable of donating a proton to the alkylated transition
metal catalytic precursor resulting in a transition metal cation,
including ammoniums, oxoniums, phosphoniums, silyliums, and
mixtures thereof, preferably ammoniums of methylamine, aniline,
dimethylamine, diethylamine, N-methylaniline, diphenylamine,
trimethylamine, triethylamine, N,N-dimethylaniline,
methyldiphenylamine, pyridine, p-bromo N,N-dimethylaniline,
p-nitro-N,N-dimethylaniline, phosphoniums from triethylphosphine,
triphenylphosphine, and diphenylphosphine, oxomiuns from ethers
such as dimethyl ether, diethyl ether, tetrahydrofuran and dioxane,
sulfoniums from thioethers, such as diethyl thioethers and
tetrahydrothiophene, and mixtures thereof. The activating cation
(L**-H).sub.d.sup.+ may also be a moiety such as silver, tropylium,
carbeniums, ferroceniums and mixtures, preferably carboniums and
ferroceniums; most preferably triphenyl carbonium. The anion
component A.sup.d- include those having the formula
[M.sup.k+Q.sub.n].sup.d- wherein k is an integer from 1 to 3; n is
an integer from 2-6; n-k=d; M is an element selected from Group 13
of the Periodic Table of the Elements, preferably boron or
aluminum, and Q is independently a hydride, bridged or unbridged
dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, substituted
hydrocarbyl, halocarbyl, substituted halocarbyl, and
halosubstituted-hydrocarbyl radicals, said Q having up to 20 carbon
atoms with the proviso that in not more than one occurrence is Q a
halide. Preferably, each Q is a fluorinated hydrocarbyl group
having 1 to 20 carbon atoms, more preferably each Q is a
fluorinated aryl group, and most preferably each Q is a
pentafluoryl aryl group. Examples of suitable A.sup.d- also include
diboron compounds as disclosed in U.S. Pat. No. 5,447,895, which is
fully incorporated herein by reference.
[0158] Illustrative, but not limiting examples of boron compounds
which may be used as an activating cocatalyst in combination with a
co-activator in the preparation of the improved catalysts of this
invention are tri-substituted ammonium salts such as:
trimethylammonium tetraphenylborate, triethylammonium
tetraphenylborate, tripropylammonium tetraphenylborate,
tri(n-butyl)ammonium tetraphenylborate, tri(tert-butyl)ammonium
tetraphenylborate, N,N-dimethylanilinium tetraphenylborate,
N,N-diethylanilinium tetraphenylborate,
N,N-dimethyl-(2,4,6-trimethylanilinium) tetraphenylborate,
trimethylammonium tetrakis(pentafluorophenyl)borate,
triethylammonium tetrakis(pentafluorophenyl)borate,
tripropylammonium tetrakis(pentafluorophenyl)borate,
tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate,
tri(sec-butyl)ammonium tetrakis(pentafluorophenyl)borate,
N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate,
N,N-diethylanilinium tetrakis(pentafluorophenyl)borate,
N,N-dimethyl-(2,4,6-trimethylanilinium)
tetrakis(pentafluorophenyl)borate, trimethylammonium
tetrakis-(2,3,4,6-tetrafluorophenyl) borate, triethylammonium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, tripropylammonium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, tri(n-butyl)ammonium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate,
dimethyl(tert-butyl)ammonium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, N,N-dimethylanilinium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, N,N-diethylanilinium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate,
N,N-dimethyl-(2,4,6-trimethylanilinium)
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, trimethylammonium
tetrakis(perfluoronaphthyl)borate, triethylammonium
tetrakis(perfluoronaphthyl)borate, tripropylammonium
tetrakis(perfluoronaphthyl)borate, tri(n-butyl)ammonium
tetrakis(perfluoronaphthyl)borate, tri(tert-butyl)ammonium
tetrakis(perfluoronaphthyl)borate, N,N-dimethylanilinium
tetrakis(perfluoronaphthyl)borate, N,N-diethylanilinium
tetrakis(perfluoronaphthyl)borate,
N,N-dimethyl-(2,4,6-trimethylanilinium)
tetrakis(perfluoronaphthyl)borate, trimethylammonium
tetrakis(perfluorobiphenyl)borate, triethylammonium
tetrakis(perfluorobiphenyl)borate, tripropylammonium
tetrakis(perfluorobiphenyl)borate, tri(n-butyl)ammonium
tetrakis(perfluorobiphenyl)borate, tri(tert-butyl)ammonium
tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium
tetrakis(perfluorobiphenyl)borate, N,N-diethylanilinium
tetrakis(perfluorobiphenyl)borate,
N,N-dimethyl-(2,4,6-trimethylanilinium)
tetrakis(perfluorobiphenyl)borate, trimethylammonium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triethylammonium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, tripropylammonium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate,
tri(n-butyl)ammonium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate,
tri(tert-butyl)ammonium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate,
N,N-dimethylanilinium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate,
N,N-diethylanilinium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate,
N,N-dimethyl-(2,4,6-trimethylanilinium)
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, and dialkyl
ammonium salts such as: di-(iso-propyl)ammonium
tetrakis(pentafluorophenyl)borate, and dicyclohexylammonium
tetrakis(pentafluorophenyl)borate; and other salts such as
tri(o-tolyl)phosphonium tetrakis(pentafluorophenyl)borate,
tri(2,6-dimethylphenyl)phosphonium
tetrakis(pentafluorophenyl)borate, tropillium tetraphenylborate,
triphenylcarbenium tetraphenylborate, triphenylphosphonium
tetraphenylborate, triethylsilylium tetraphenylborate,
benzene(diazonium)tetraphenylborate, tropillium
tetrakis(pentafluorophenyl)borate, triphenylcarbenium
tetrakis(pentafluorophenyl)borate, triphenylphosphonium
tetrakis(pentafluorophenyl)borate, triethylsilylium
tetrakis(pentafluorophenyl)borate, benzene(diazonium)
tetrakis(pentafluorophenyl)borate, tropillium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, triphenylcarbenium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, triphenylphosphonium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, triethylsilylium
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, benzene(diazonium)
tetrakis-(2,3,4,6-tetrafluorophenyl)borate, tropillium
tetrakis(perfluoronaphthyl)borate, triphenylcarbenium
tetrakis(perfluoronaphthyl)borate, triphenylphosphonium
tetrakis(perfluoronaphthyl)borate, triethylsilylium
tetrakis(perfluoronaphthyl)borate, benzene(diazonium)
tetrakis(perfluoronaphthyl)borate, tropillium
tetrakis(perfluorobiphenyl)borate, triphenylcarbenium
tetrakis(perfluorobiphenyl)borate, triphenylphosphonium
tetrakis(perfluorobiphenyl)borate, triethylsilylium
tetrakis(perfluorobiphenyl)borate, benzene(diazonium)
tetrakis(perfluorobiphenyl)borate, tropillium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triphenylcarbenium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate,
triphenylphosphonium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triethylsilylium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, and
benzene(diazonium)
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate.
[0159] Most preferably, the ionic stoichiometric activator
(L**-H).sub.d.sup.+(A.sup.d) is N,N-dimethylanilinium
tetrakis(perfluorophenyl)borate, N,N-dimethylanilinium
tetrakis(perfluoronaphthyl)borate, N,N-dimethylanilinium
tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triphenylcarbenium
tetrakis(perfluoronaphthyl)borate, triphenylcarbenium
tetrakis(perfluorobiphenyl)borate, triphenylcarbenium
tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, or
triphenylcarbenium tetra(perfluorophenyl)borate.
[0160] The catalyst precursors can also be activated with
cocatalysts or activators that comprise non-coordinating anions
containing metalloid-free cyclopentadienide ions. These are
described in U.S. Patent Publication 2002/0058765 A1, published on
16 May 2002, and for the instant invention, require the addition of
a co-activator to the catalyst pre-cursor. "Compatible"
non-coordinating anions are those which are not degraded to
neutrality when the initially formed complex decomposes. Further,
the anion will not transfer an anionic substituent or fragment to
the cation so as to cause it to form a neutral transition metal
compound and a neutral by-product from the anion. Preferred
non-coordinating anions useful in accordance with this invention
are those that are compatible, stabilize the transition metal
complex cation in the sense of balancing its ionic charge at +1,
yet retain sufficient lability to permit displacement by an
ethylenically or acetylenically unsaturated monomer during
polymerization. These types of cocatalysts are sometimes used with
scavengers such as but not limited to tri-iso-butylaluminum,
tri-n-octylaluminum, tri-n-hexylaluminum, triethylaluminum or
trimethylaluminum.
[0161] Invention processes also can employ cocatalyst compounds or
activator compounds that are initially neutral Lewis acids but form
a cationic metal complex and a noncoordinating anion, or a
zwitterionic complex upon reaction with the alkylated transition
metal compounds. The alkylated metallocene compound is formed from
the reaction of the catalyst pre-cursor and the co-activator. For
example, tris(pentafluorophenyl) boron or aluminum act to abstract
a hydrocarbyl ligand to yield an invention cationic transition
metal complex and stabilizing noncoordinating anion, see EP-A-0 427
697 and EP-A-0 520 732 for illustrations of analogous Group-4
metallocene compounds. Also, see the methods and compounds of
EP-A-0 495 375. For formation of zwitterionic complexes using
analogous Group 4 compounds, see U.S. Pat. Nos. 5,624,878;
5,486,632; and 5,527,929.
[0162] Additional neutral Lewis-acids are known in the art and are
suitable for abstracting formal anionic ligands. See in particular
the review article by E. Y.-X. Chen and T. J. Marks, "Cocatalysts
for Metal-Catalyzed Olefin Polymerization: Activators, Activation
Processes, and Structure-Activity Relationships", Chem. Rev., 100,
1391-1434 (2000).
[0163] When the cations of noncoordinating anion precursors are
Bronsted acids such as protons or protonated Lewis bases (excluding
water), or reducible Lewis acids such as ferrocenium or silver
cations, or alkali or alkaline earth metal cations such as those of
sodium, magnesium or lithium, the catalyst-precursor-to-activator
molar ratio may be any ratio. Combinations of the described
activator compounds may also be used for activation.
[0164] When an ionic or neutral stoichiometric activator (such as
an NCA) is used, the catalyst-precursor-to-activator molar ratio is
from 1:10 to 1:1; 1:10 to 10:1; 1:10 to 2:1; 1:10 to 3:1; 1:10 to
5:1; 1:2 to 1.2:1; 1:2 to 10:1; 1:2 to 2:1; 1:2 to 3:1; 1:2 to 5:1;
1:3 to 1.2:1; 1:3 to 10:1; 1:3 to 2:1; 1:3 to 3:1; 1:3 to 5:1; 1:5
to 1:1; 1:5 to 10:1; 1:5 to 2:1; 1:5 to 3:1; 1:5 to 5:1; 1:1 to
1:1.2. The catalyst-precursor-to-co-activator molar ratio is from
1:500 to 1:1, 1:100 to 100:1; 1:75 to 75:1; 1:50 to 50:1; 1:25 to
25:1; 1:15 to 15:1; 1:10 to 10:1; 1:5 to 5:1, 1:2 to 2:1; 1:100 to
1:1; 1:75 to 1:1; 1:50 to 1:1; 1:25 to 1:1; 1:15 to 1:1; 1:10 to
1:1; 1:5 to 1:1; 1:2 to 1:1; 1:10 to 2:1. Preferred activators and
activator/co-activator combinations include methylalumoxane,
modified methylalumoxane, mixtures of methylalumoxane with
dimethylanilinium tetrakis(pentafluorophenyl)borate or
tris(pentafluorophenyl)boron, and mixtures of trimethyl aluminum
with dimethylanilinium tetrakis(pentafluorophenyl)borate or
tris(pentafluorophenyl)boron In some embodiments, scavenging
compounds are used with stoichiometric activators. Typical aluminum
or boron alkyl components useful as scavengers are represented by
the general formula R.sup.xJZ.sub.2 where J is aluminum or boron,
R.sup.x is as previously defined above, and each Z is independently
R.sup.x or a different univalent anionic ligand such as halogen
(Cl, Br, I), alkoxide (OR.sup.x) and the like. Most preferred
aluminum alkyls include triethylaluminum, diethylaluminum chloride,
tri-iso-butylaluminum, tri-n-octylaluminum. tri-n-hexylaluminum,
trimethylaluminum and the like. Preferred boron alkyls include
triethylboron. Scavenging compounds may also be alumoxanes and
modified alumoxanes including methylalumoxane and modified
methylalumoxane.
Supported Catalysts
[0165] Supported catalysts and or supported catalyst systems may be
used to prepare PAO's. To prepare uniform supported catalysts, the
catalyst precursor preferably dissolves in the chosen solvent. The
term "uniform supported catalyst" means that the catalyst
precursor, the activator, and or the activated catalyst approach
uniform distribution upon the support's accessible surface area,
including the interior pore surfaces of porous supports. Some
embodiments of supported catalysts prefer uniform supported
catalysts; other embodiments show no such preference.
[0166] Useful supported catalyst systems may be prepared by any
method effective to support other coordination catalyst systems,
effective meaning that the catalyst so prepared can be used for
oligomerizing or polymerizing olefins in a heterogenous process.
The catalyst precursor, activator, co-activator (if needed),
suitable solvent, and support may be added in any order or
simultaneously.
[0167] By one method, the activator, dissolved in an appropriate
solvent such as toluene, may be stirred with the support material
for 1 minute to 10 hours to prepare the supported catalyst. The
total solution volume (of the catalyst solution, the activator
solution or both) may be greater than the pore volume of the
support, but some embodiments limit the total solution volume below
that needed to form a gel or slurry (about 90% to 400%, preferably
about 100-200%, of the pore volume). The mixture is optionally
heated from 30-200.degree. C. during this time. The catalyst
precursor may be added to this mixture as a solid, if a suitable
solvent is employed in the previous step, or as a solution.
Alternatively, the mixture can be filtered, and the resulting solid
mixed with a catalyst precursor solution. Similarly, the mixture
may be vacuum dried and mixed with a catalyst precursor solution.
The resulting catalyst mixture is then stirred for 1 minute to 10
hours, and the supported catalyst is either filtered from the
solution and vacuum dried or subjected to evaporation to remove the
solvent.
[0168] Alternatively, the catalyst precursor and activator may be
combined in solvent to form a solution. The support is then added
to the solution, and the resulting mixture is stirred for 1 minute
to 10 hours. The total activator/catalyst-precursor solution volume
may be greater than the pore volume of the support, but some
embodiments limit the total solution volume below that needed to
form a gel or slurry (about 90% to 400%, preferably about 100-200%
of the pore volume). After stirring, the residual solvent is
removed under vacuum, typically at ambient temperature and over
10-16 hours; however, greater or lesser times and temperatures may
be used.
[0169] The catalyst precursor may also be supported absent the
activator; in this case, the activator (and co-activator if needed)
is added to a the liquid phase of a slurry process. For example, a
solution of catalyst precursor may be mixed with a support material
for a period of about 1 minute to 10 hours. The resulting
precatalyst mixture may be filtered from the solution and dried
under vacuum or treated with evaporation to remove the solvent. The
total catalyst-precursor-solution volume may be greater than the
support's pore volume, but some embodiments limit the total
solution volume below that needed to form a gel or slurry (about
90% to 400%, preferably about 100-200% of the pore volume).
[0170] Additionally, two or more different catalyst precursors may
be placed on the same support using any of the support methods
disclosed above. Likewise, two or more activators or an activator
and a co-activator, may be placed on the same support. Suitable
solid particle supports are typically comprised of polymeric or
refractory oxide materials, each being preferably porous. Any
support material that has an average particle size greater than 10
.mu.m is suitable for use in this invention. Various embodiments
select a porous support material, such as for example, talc,
inorganic oxides, inorganic chlorides, for example magnesium
chloride and resinous support materials such as polystyrene
polyolefin or polymeric compounds or any other organic support
material and the like. Some embodiments select inorganic oxide
materials as the support material including Group-2, -3, -4, -5,
-13, or -14 metal or metalloid oxides. Some embodiments select the
catalyst support materials to include silica, alumina,
silica-alumina, and their mixtures. Other inorganic oxides may
serve either alone or in combination with the silica, alumina, or
silica-alumina. These are magnesia, titania, zirconia, and the
like. Lewis acidic materials such as montmorillonite and similar
clays may also serve as a support. In this case, the support can
optionally double as an activator component. But additional
activator may also be used. In some cases, a special family of
solid support commonly known as MCM-41 can also be used. MCM-41 is
a new class of unique crystalline support and can be prepared with
tunable pore size and tunable acidity when modified with a second
component. A detailed description of this class of materials and
their modification can be found in U.S. Pat. No. 5,264,203.
[0171] The support material may be pretreated by any number of
methods. For example, inorganic oxides may be calcined, chemically
treated with dehydroxylating agents such as aluminum alkyls and the
like, or both.
[0172] As stated above, polymeric carriers will also be suitable in
accordance with the invention, see for example the descriptions in
WO 95/15815 and U.S. Pat. No. 5,427,991. The methods disclosed may
be used with the catalyst compounds, activators or catalyst systems
of this invention to adsorb or absorb them on the polymeric
supports, particularly if made up of porous particles, or may be
chemically bound through functional groups bound to or in the
polymer chains.
[0173] Useful catalyst carriers may have a surface area of from
10-700 m.sup.2/g, and or a pore volume of 0.1-4.0 cc/g and or an
average particle size of 10-500 p.m. Some embodiments select a
surface area of 50-500 m.sup.2/g, and or a pore volume of 0.5-3.5
cc/g, and or an average particle size of 20-200 p.m. Other
embodiments select a surface area of 100-400 m.sup.2/g, and or a
pore volume of 0.8-3.0 cc/g, and or an average particle size of
30-100 .mu.m. Invention carriers typically have a pore size of
10-1000 Angstroms, alternatively 50-500 Angstroms, or 75-350
Angstroms. The metallocenes and or the metallocene/activator
combinations are generally deposited on the support at a loading
level of 10-100 micromoles of catalyst precursor per gram of solid
support; alternately 20-80 micromoles of catalyst precursor per
gram of solid support; or 40-60 micromoles of catalyst precursor
per gram of support. But greater or lesser values may be used
provided that the total amount of solid catalyst precursor does not
exceed the support's pore volume.
[0174] The metallocenes and or the metallocene/activator
combinations can be supported for gas-phase, bulk, or slurry
polymerization, or otherwise as needed. Numerous support methods
are known for catalysts in the olefin polymerization art,
particularly alumoxane-activated catalysts; all are suitable for
use herein. See, for example, U.S. Pat. Nos. 5,057,475 and
5,227,440. An example of supported ionic catalysts appears in WO
94/03056. U.S. Pat. No. 5,643,847 and WO 96/04319A which describe a
particularly effective method. Both polymers and inorganic oxides
may serve as supports, see U.S. Pat. Nos. 5,422,325, 5,427,991,
5,498,582 and 5,466,649, and international publications WO 93/11172
and WO 94/07928.
[0175] In another preferred embodiment, the metallocene and or
activator (with or without a support) are combined with an
alkylaluminum compound, preferably a trialkylaluminum compound,
prior to entering the reactor. Preferably the alkylaluminum
compound is represented by the formula: R.sub.3Al, where each R is
independently a C1 to C20 alkyl group; preferably the R groups are
independently selected from the group consisting of methyl, ethyl,
propyl, isopropyl, butyl, isobutyl, n-butyl, pentyl, isopentyl,
n-pentyl, hexyl, isohexyl, n-hexyl, heptyl, octyl, isooctyl,
n-octyl, nonyl, isononyl, n-nonyl, decyl, isodecyl, n-decyl,
undecyl, isoundecyl, n-undecyl, dodecyl, isododecyl, and n-dodecyl,
preferably isobutyl, n-octyl, n-hexyl, and n-dodecyl. Preferably
the alkylaluminum compound is selected from tri-isobutyl aluminum,
tri n-octyl aluminum, tri-n-hexyl aluminum, and tri-n-dodecyl
aluminum.
Monomers
[0176] In a preferred embodiment the catalyst compounds described
herein are used to polymerize or oligomerize any unsaturated
monomer or monomers. Preferred monomers include C.sub.5 to C.sub.24
olefins, preferably C.sub.6 to C.sub.14 olefins, more preferably
C.sub.8 to C.sub.12 olefins. In some embodiments preferred monomers
include linear, branched or cyclic alpha-olefins, preferably
C.sub.6 to C.sub.20 alpha-olefins, preferably C.sub.6 to C.sub.14
alpha-olefins, and more preferably C.sub.8 to C.sub.12
alpha-olefins. Preferred olefin monomers may be one or more of
hexene, heptene, octene, nonene, decene, dodecene,
3-methyl-1-butene, and tetradecene.
[0177] In a preferred embodiment, the process described herein may
be used to produce homo-oligomers or co-oligomers (for the purposes
of this invention and the claims thereto, a co-oligmer may comprise
two, three, four, or more different monomer units). Preferred
oligomers produced herein include homo-oligomers or co-oligomers of
any of the above monomers. In a preferred embodiment the oligomer
is a homo-oligomer of any C.sub.8 to C.sub.12 alpha-olefin.
Preferably the oligomer is a homo-oligomer of 1-hexene, 1-heptene,
1-octene, 1-nonene, 1-decene, 1-undecene, or 1-dodecene. Preferably
the oligomer is a homo-oligomer of decene. In another embodiment
the oligomer is a co-oligomer comprising decene and one or more of
any of the monomers listed above.
[0178] The alpha-olefins used to make PAOs include, but are not
limited to, C.sub.5 to C.sub.24 alpha-olefins, with the C.sub.6 to
C.sub.14 alpha-olefins, such as 1-hexene, 1-heptene, 1-octene,
1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene and
1-tetradecene being preferred. A preferred group of
polyalpha-olefins are poly-1-hexene, polyl-heptene, poly-1-octene,
poly-1-nonene, poly-1-decene, polyl-undencen, poly-1-dodecene,
poly-1-tridecene, and poly-1-tetradecene, although the dimers of
higher olefins in the range of C.sub.12 to C.sub.18 can be present
in the final products. Useful PAO's are preferably dimers, trimers,
tetramers, pentamers, and higher oligomers or polymers with carbon
numbers starting from C.sub.20 and higher made from C.sub.4 to
C.sub.18 alpha-olefins in one embodiment, and oligomers or polymers
with carbon number starting from C.sub.20 and higher made from
C.sub.6 to C.sub.14 alpha-olefins in another embodiment. Suitable
olefins include 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene,
1-nonene, 1-decene, 1-undodecene and 1-dodecene, 1-tridecene,
1-tetradecene. In one embodiment, the olefin is 1-decene, and the
PAO is a mixture of dimers, trimers, tetramers and pentamers (and
higher) of 1-decene. In another embodiment, the olefin is 1-decene,
and the PAO is a mixture of trimers, tetramers and pentamers (and
higher) of 1-decene. In another embodiment, the olefin is 1-octene,
and the PAO is a mixture of trimers, tetramers and pentamers (and
higher) of 1-octene. In another embodiment, the olefin is 1-hexene,
and the PAO is a mixture of tetramers and pentamers (and higher) of
1-hexene.
[0179] In a preferred embodiment, the PAO comprises two or more
monomers, preferably three or more monomers, preferably four or
more monomers, preferably five or more monomers. For example, a C8,
C10, C12-linear alpha-olefin mixture, or a C6, C7, C8, C9, C10,
C11, C12, C13, C14-linear alpha-olefin mixture, or a C4, C6, C8,
C10, C12, C14, C16, C18-linear alpha-olefin mixture can be used as
a feed.
In an alternate embodiment, the PAO comprises less than 50 mole %
of C2, C3 and C4 monomers, preferably less than 40 mole %,
preferably less than 30 mole %, preferably less than 20 mole %,
preferably less than 10 mole %, preferably less than 5 mole %,
preferably less than 3 mole %, preferably 0%. Specifically, in an
alternate embodiment, the PAO comprises less than 50 mole % of
ethylene, propylene and butene, preferably less than 40 mole %,
preferably less than 30 mole %, preferably less than 20 mole %,
preferably less than 10 mole %, preferably less than 5 mole %,
preferably less than 3 mole %, preferably 0%. In another
embodiment, the PAO comprises less than 40 mole % of ethylene. In
another embodiment, the PAO comprises less than 40 mole % of
propylene. In another embodiment, the PAO comprises less than 40
mole % of butene. In another embodiment, the PAO comprises less
than 10 mole % of ethylene. In another embodiment, the PAO
comprises less than 10 mole % of propylene. In another embodiment,
the PAO comprises less than 10 mole % of butene. In another
embodiment, the PAO comprises less than 1 mole % of ethylene. In
another embodiment, the PAO comprises less than 1 mole % of
propylene. In another embodiment, the PAO comprises less than 1
mole % of butene.
[0180] The alpha-olefins used herein can be produced directly from
ethylene growth process as practiced by several commercial
production processes, or they can be produced from Fischer-Tropsch
hydrocarbon synthesis from CO/H.sub.2 syngas, or from metathesis of
internal olefins with ethylene, or from cracking of petroleum or
Fischer-Tropsch synthetic wax at high temperature, or any other
alpha-olefin synthesis routes. A preferred feed for this invention
is preferably at least 80 weight % alpha-olefin (preferably linear
alpha olefin), preferably at least 90 weight % alpha-olefin
(preferably linear alpha olefin), more preferably 100% alpha-olefin
(preferably linear alpha olefin). However, alpha-olefin mixtures
can also be used as feeds in this invention, especially if the
other components are internal-olefins, branched olefins, paraffins,
cyclic paraffins, aromatics (such as toluene and or xylenes). These
components have diluent effects and are believed to not have a
substantial detrimental effect on the polymerization of
alpha-olefins. In other words, the process described herein can
selectively convert alpha-olefins in a mixture and leave the other
components unreacted. This is particularly useful when ethylene is
not present in the mixture. This technology can be used to separate
out alpha-olefins from a mixture by selectively reacting them with
polymerization or oligomerization catalyst systems completely
eliminating the need to separate alpha-olefins from the remainder
of the components in a mixed feedstream. This is economically
advantageous, for example, in a process utilizing Fisher-Tropsch
synthesis olefin product streams containing alpha-olefins,
internal-olefins and branched olefins. Such a mixture can be fed to
the oligomerization technology as described herein and to
selectively react away the alpha-olefin. No separate step to
isolate the alpha-olefin is needed. Another example of the utility
of this process involves-alpha-olefins produced by the metathesis
of internal olefins with ethylene, which may contain some internal
olefins. This mixed olefin base stock feed can be reacted as is in
the polymerization/oligomerization process of the present
invention, which selectively converts the alpha-olefins into lube
products. Thus one can use the alpha-olefin for the base stock
synthesis without having to separate the alpha-olefin from internal
olefin. This can bring a significant improvement in process
economics.
[0181] In a preferred embodiment, the PAO's produced herein may
contain monomers having branches at least 2, preferably at least 3
carbons away from the alpha-unsaturation, such 4-methyl-1-decene,
4-ethyl-1-decene, or 4-methyl-1-hexene, 4-methyl-1-pentene, etc.
These olefins may be present in the linear alpha-olefins from the
manufacturing process or they can be added deliberately. The
copolymers of slightly branched alpha-olefins with completely
linear alpha-olefins have improved low temperature properties.
[0182] In a preferred embodiment, any of the PAO's described herein
may comprise at least 50 mole % 5 to 24 carbon atoms and from 0.5
to 20 mole % ethylene, where at least 80% of the ethylene present
in the polyalpha-olefin is present in runs of 1 to 35 carbons or
less as measured by Carbon 13 NMR. Preferably any of the PAO's
described herein may comprise at least 60 mole % 5 to 24 carbon
atoms (preferably at least 70 mole %, preferably at least 80 mole
%, preferably at least 85 mole %, preferably at least 90 mole %,
preferably at least 95 mole %) and from 0.5 to 20 mole % ethylene
(preferably from 1 to 15 mole %, preferably from 2 to 10 mole %,
preferably form 2 to 5 mole %), where at least 80% (preferably at
least 85%, preferably at least 90%, preferably at least 95%,
preferably at least 98%, preferably 100%) of the ethylene present
in the polyalpha-olefin is present in runs of 1 to 35 carbons
(preferably 1 to 30, preferably 1 to 25, preferably 1 to 20,
preferably 1 to 15, preferably 1 to 10, preferably 1 to 5) as
measured by Carbon 13 NMR.
Polymerization/Oligomerization Process
[0183] Many polymerization/oligomerization processes and reactor
types used for metallocene-catalyzed polymerizations or
oligomerizations such as solution, slurry, and bulk polymerization
or oligomerization processed can be used in this invention. In some
embodiments, if a solid or supported catalyst is used, a slurry or
continuous fixed bed or plug flow process is suitable. In a
preferred embodiment, the monomers are contacted with the
metallocene compound and the activator in the solution phase, bulk
phase, or slurry phase, preferably in a continuous stirred tank
reactor, continuous tubular reactor, or a batch reactor. In a
preferred embodiment, the temperature in any reactor used herein is
from -10.degree. C. to 250.degree. C., preferably from 30.degree.
C. to 220.degree. C., preferably from 50.degree. C. to 180.degree.
C., preferably from 60.degree. C. to 170.degree. C. In a preferred
embodiment, the pressure in any reactor used herein is from 0.1 to
100 atmospheres, preferably from 0.5 to 75 atmospheres, preferably
from 1 to 50 atmospheres. In another embodiment, the pressure is
any reactor used herein is from 1 to 50,000 atmospheres, preferably
1 to 25,000 atmospheres. In another embodiment, the monomer(s),
metallocene and activator are contacted for a residence time of 1
second to 100 hours, preferably 30 seconds to 50 hours, preferably
2 minutes to 6 hours, preferably 1 minute to 4 hours. In another
embodiment solvent or diluent is present in the reactor and is
preferably selected from the group consisting of butanes, pentanes,
hexanes, heptanes, octanes, nonanes, decanes, undecanes, dodecanes,
tridecanes, tetradecanes, pentadecanes, hexadecanes, toluene,
o-xylene, m-xylene, p-xylene, ethylbenzene, isopropylbenzene, and
n-butylbenzene; preferably toluene and or xylenes and or
ethylbenzene, normal paraffins (such as Norpar solvents available
for ExxonMobil Chemical Company in Houston, Tex.), or isoparaffin
solvents (such as Isopar solvents available for ExxonMobil Chemical
Company in Houston, Tex.). These solvents or diluents are usually
pre-treated in same manners as the feed olefins.
[0184] Typically, in the processes of this invention, one or more
transition metal compounds, one or more activators, and one or more
monomers are contacted to produce polymer or oligomer. These
catalysts may be supported and as such will be particularly useful
in the known slurry, solution, or bulk operating modes conducted in
single, series, or parallel reactors. If the catalyst, activator or
co-activator is a soluble compound, the reaction can be carried out
in a solution mode. Even if one of the components is not completely
soluble in the reaction medium or in the feed solution, either at
the beginning of the reaction or during or at the later stages of
the reaction, a solution or slurry type operation is still
applicable. In any instance, the catalyst components, dissolved or
suspended insolvents, such as toluene or other conveniently
available aromatic solvents, or in aliphatic solvent, or in the
feed alpha-olefin stream, are fed into the reactor under inert
atmosphere (usually nitrogen or argon blanketed atmosphere) to
allow the polymerization or oligomerization to take place. The
polymerization or oligomerization can be run in a batch mode, where
all the components are added into a reactor and allowed to react to
a pre-designed degree of conversion, either to partial conversion
or full conversion. Subsequently, the catalyst is deactivated by
any possible means, such as exposure to air or water, or by
addition of alcohols or solvents containing deactivating agents.
The polymerization or oligomerization can also be carried out in a
semi-continuous operation, where feeds and catalyst system
components are continuously and simultaneously added to the reactor
so as to maintain a constant ratio of catalyst system components to
feed olefin(s). When all feeds and catalyst components are added,
the reaction is allowed to proceed to a pre-determined stage. The
reaction is then discontinued by catalyst deactivation in the same
manner as described for batch operation. The polymerization or
oligomerization can also be carried out in a continuous operation,
where feeds and catalyst system components are continuously and
simultaneously added to the reactor so to maintain a constant ratio
of catalyst system and feed olefins. The reaction product is
continuously withdrawn from the reactor, as in a typical continuous
stirred tank reactor (CSTR) operation. The residence times of the
reactants are controlled by a pre-determined degree of conversion.
The withdrawn product is then typically quenched in the separate
reactor in a similar manner as other operation. In a preferred
embodiment, any of the processes to prepare PAO's described herein
are continuous processes. Preferably the continuos process
comprises the steps of a) continuously introducing a feed stream
comprising at least 10 mole % of the one or more C5 to C24
alpha-olefins into a reactor, b) continuously introducing the
metallocene compound and the activator into the reactor, and c)
continuously withdrawing the polyalpha-olefin from the reactor. In
another embodiment, the continuous process comprises the step of
maintaining a partial pressure of hydrogen in the reactor of 200
psi (1379 kPa) or less, based upon the total pressure of the
reactor, preferably 150 psi (1034 kPa) or less, preferably 100 psi
(690 kPa) or less, preferably 50 psi (345 kPa) or less, preferably
25 psi (173 kPa) or less, preferably 10 psi (69 kPa) or less.
Alternately the hydrogen, if present is present in the reactor at
1000 ppm or less by weight, preferably 750 ppm or less, preferably
500 ppm or less, preferably 250 ppm or less, preferably 100 ppm or
less, preferably 50 ppm or less, preferably 25 ppm or less,
preferably 10 ppm or less, preferably 5 ppm or less. Alternately
the hydrogen, if present, is present in the feed at 1000 ppm or
less by weight, preferably 750 ppm or less, preferably 500 ppm or
less, preferably 250 ppm or less, preferably 100 ppm or less,
preferably 50 ppm or less, preferably 25 ppm or less, preferably 10
ppm or less, preferably 5 ppm or less.
[0185] Preferred reactors range in size from 2 ml and up. Usually,
it is preferable to use reactors larger than one liter in volume
for commercial production. The production facility may have one
single reactor or several reactors arranged in series or in
parallel or in both to maximize productivity, product properties
and general process efficiency. The reactors and associated
equipments are usually pre-treated to ensure proper reaction rates
and catalyst performance. The reaction is usually conducted under
inert atmosphere, where the catalyst system and feed components
will not be in contact with any catalyst deactivator or poison
which is usually polar oxygen, nitrogen, sulfur or acetylenic
compouds.
[0186] One or more reactors in series or in parallel may be used in
the present invention. The transition metal compound, activator and
when required, co-activator, may be delivered as a solution or
slurry in a solvent or in the alpha-olefin feed stream, either
separately to the reactor, activated in-line just prior to the
reactor, or preactivated and pumped as an activated solution or
slurry to the reactor. Polymerizations/oligomerizations are carried
out in either single reactor operation, in which monomer, or
several monomers, catalyst/activator/co-activator, optional
scavenger, and optional modifiers are added continuously to a
single reactor or in series reactor operation, in which the above
components are added to each of two or more reactors connected in
series. The catalyst components can be added to the first reactor
in the series. The catalyst component may also be added to both
reactors, with one component being added to first reaction and
another component to other reactors. In one preferred embodiment,
the precatalyst is activated in the reactor in the presence of
olefin. In another embodiment, the precatalyst such as the
dichloride form of the metallocenes is pre-treated with alkylalumum
reagents, especially, triisobutylaluminum, tri-n-hexylaluminum
and/or tri-n-octylaluminum, followed by charging into the reactor
containing other catalyst component and the feed olefins, or
followed by pre-activation with the other catalyst component to
give the fully activated catalyst, which is then fed into the
reactor containing feed olefins. In another alternative, the
pre-catalyst metallocene is mixed with the activator and/or the
co-activator and this activated catalyst is then charged into
reactor, together with feed olefin stream containing some
scanvenger or co-activator. In another alternative, the whole or
part of the co-activator is pre-mixed with the feed olefins and
charged into the reactor at the same time as the other catalyst
solution containing metallocene and activators and/or
co-activator.
[0187] In some embodiments, a small amount of poison scavenger,
such as trialkylaluminum (trimethylaluminum, triethylaluminum,
triisopropylaluminum, triisobutylaluminum, tri-n-hexylaluminum,
tri-n-octylaluminum) or methylalumoxane is added to the feed olefin
stream to further improve catalyst activity. In a preferred
embodiment, the monomers are contacted with an alkylaluminum
compound, preferably a trialkylaluminum compound, prior to being
introduced into the reactor. In another preferred embodiment, the
metallocene and or activator are combined with an alkylaluminum
compound, preferably a trialkylaluminum compound, prior to entering
the reactor. Preferably the alkylaluminum compound is represented
by the formula: R.sub.3Al, where each R is independently a C1 to
C20 alkyl group, preferably the R groups are independently selected
from the group consisting of methyl, ethyl, propyl, isopropyl,
butyl, isobutyl, n-butyl, pentyl, isopentyl, n-pentyl, hexyl,
isohexyl, n-hexyl, heptyl, octyl, isocotyl, n-octyl, nonyl,
isononyl, n-nonyl, decyl, isodecyl, n-cecyl, undecyl, isoundecyl,
n-undecyl, dodecyl, isododecyl, and n-dodecyl, preferably isobutyl,
n-octyl, n-hexyl, and n-dodecyl. Preferably the alkylaluminum
compound is selected from tri-isobutylaluminum, tri
n-octylaluminum, tri-n-hexylaluminum, and
tri-n-dodecylaluminum.
[0188] In one embodiment of any of the process described herein the
feed olefins and or solvents are treated to remove catalyst
poisons, such as peroxides, oxygen or nitrogen-containing organic
compounds or acetylenic compounds. The treatment of the linear
alpha-olefin with an activated 13.times. molecular sieve and a
de-oxygenate catalyst, i.e., a reduced copper catalyst, increased
catalyst productivity more than 10-fold. Alternatively, the feed
olefins and or solvents are treated with an activated molecular
sieve, such as 3A, 4A, 8A or 13.times. molecular sieve, and/or in
combination with an activated alumina or an activated de-oxygenated
catalyst. Such treatment will increase catalyst productivity 2- to
10-fold or more. The improved process also includes special
treatment of the feed olefins to remove catalyst poisons, such as
peroxides, oxygen, sulfur or nitrogen-containing organic compounds
or other trace impurities. This treatment can increase catalyst
productivity substantially (typically more than 10-fold).
Preferably the feed olefins are contacted with a molecular sieve,
activated alumina, silica gel, oxygen removing catalyst, and or
purifying clays to reduce the heteroatom-containing compounds in
the feed, preferably th below 50 ppm, preferably below 10 ppm.
[0189] The catalyst compositions can be used individually or can be
mixed with other known polymerization catalysts to prepare polymer
or oligomer blends. Monomer and catalyst selection allows polymer
or oligomer blend preparation under conditions analogous to those
using individual catalysts. Polymers having increased MWD are
available from polymers made with mixed catalyst systems and can
thus be achieved. Mixed Catalyst can comprise two or more catalyst
precursors and or two or more activators.
[0190] Generally, when using metallocene catalysts, after
pre-treatment of feed olefins, solvents, diluents and after
precautions to keep the catalyst component stream(s) and reactor
free of impurities, the reaction should proceed well. In some
embodiments, when using metallocene catalysts, particularly when
they are immobilized on a support, the complete catalyst system
will additionally comprise one or more scavenging compounds. Here,
the term scavenging compound means a compound that removes polar
impurities from the reaction environment. These impurities
adversely affect catalyst activity and stability. Typically,
purifying steps are usually used before introducing reaction
components to a reaction vessel. But such steps will rarely allow
polymerization or oligomerization without using some scavenging
compounds. Normally, the polymerization process will still use at
least small amounts of scavenging compounds.
[0191] Typically, the scavenging compound will be an organometallic
compound such as the Group-13 organometallic compounds of U.S. Pat.
Nos. 5,153,157, 5,241,025 and WO-A-91/09882, WO-A-94/03506,
WO-A-93/14132, and that of WO 95/07941. Exemplary compounds include
triethylaluminum, triethylborane, tri-iso-butylaluminum,
diisobutylaluminum hydride, methylalumoxane, iso-butylalumoxane,
and tri-n-octylaluminum. Those scavenging compounds having bulky or
C.sub.6-C.sub.20 linear hydrocarbyl substituents connected to the
metal or metalloid center usually minimize adverse interaction with
the active catalyst. Examples include triethylaluminum, but more
preferably, bulky compounds such as tri-iso-butyl aluminum,
tri-iso-prenyl aluminum, and long-chain linear alkyl-substituted
aluminum compounds, such as tri-n-hexyl aluminum, tri-n-octyl
aluminum, or tri-n-dodecyl aluminum. When alumoxane is used as the
activator, any excess over that needed for activation will scavenge
impurities and additional scavenging compounds may be unnecessary.
Alumoxanes also may be added in scavenging quantities with other
activators, e.g., methylalumoxane,
[Me.sub.2HNPh].sup.+[B(pfp).sub.4].sup.- or B(pfp).sub.3, where pfp
is perfluorophenyl (C.sub.6F.sub.5), Me is methyl and Ph is
phenyl.
[0192] In a preferred embodiment ethylene is present in the feed at
10 mole % or less, preferably 0.5 to 8 moles %, preferably 0.5 to 5
mole %, preferably from 1 to 3 mole %
[0193] The PAO's described herein can also be produced in
homogeneous solution processes. Generally this involves
polymerization or oligomerization in a continuous reactor in which
the polymer formed and the starting monomer and catalyst materials
supplied, are agitated to reduce or avoid concentration or
temperature gradients. Temperature control in the reactor is
generally obtained by balancing the heat of polymerization and with
reactor cooling by reactor jackets or cooling coils or a cooled
side-stream of reactant to cool the contents of the reactor, auto
refrigeration, pre-chilled feeds, vaporization of liquid medium
(diluent, monomers or solvent) or combinations of the above.
Adiabatic reactors with pre-chilled feeds may also be used. The
reactor temperature depends on the catalyst used and the product
desired. Higher temperatures tend to give lower molecular weights
and lower temperatures tend to give higher molecular weights,
however this is not a hard and fast rule. In general, the reactor
temperature preferably can vary between about 0.degree. C. and
about 300.degree. C., more preferably from about 10.degree. C. to
about 230.degree. C., and most preferably from about 25.degree. C.
to about 200.degree. C. Usually, it is important to control the
reaction temperature as pre-determined. In order to produce fluids
with narrow molecular distribution, such as to promote the highest
possible shear stability, it is useful to control the reaction
temperature to obtain minimum of temperature fluctuation in the
reactor or over the course of the reaction time. If multiple
reactors are used in series or in parallel, it is useful to keep
the temperature constant in a pre-determined value to minimize any
broadening of molecular weight distribution. In order to produce
fluids with broad molecular weight distribution, one can adjust the
reaction temperature swing or fluctuation, or as in series
operation, the second reactor temperature is preferably higher than
the first reactor temperature. In parallel reactor operation, the
temperatures of the two reactors are independent. Or one can use
two types of metallocene catalysts.
[0194] The pressure in any reactor used herein can vary from about
0.1 atmosphere to 100 atmosphere (1.5 psi to 1500 psi), preferably
from 0.5 bar to 75 atm (8 psi-1125 psi), most preferably from 1.0
to 50 atm (15 psi to 750 psi). The reaction can be carried out
under the atmosphere of nitrogen or with some hydrogen. Sometimes a
small amount of hydrogen is added to the reactor to improve the
catalyst. The amount of hydrogen is preferred to keep at such a
level to improve catalyst productivity, but not induce any
hydrogenation of olefins, especially the feed alpha-olefins because
the conversion of alpha-olefins into saturated paraffins is very
detrimental to the efficiency of the process. The amount of
hydrogen partial pressure is preferred to be kept low, less than
100 psi, prefer less than 50 psi, preferably less than 25 psi,
preferably less than 10 psi, preferably less than 5 psi, preferably
less than 1 psi. In a particularly preferred embodiment in any of
the process described herein the concentration of hydrogen in the
reactant phase is less than 100 ppm, preferably less than 50 ppm,
preferably less than 10 ppm, preferably less than 1 ppm. In a
particularly preferred embodiment in any of the process described
herein the concentration of hydrogen in the reactor is kept at a
partial pressure of 200 psi (1379 kPa) or less, based upon the
total pressure of the reactor, preferably 150 psi (1034 kPa) or
less, preferably 100 psi (690 kPa) or less, preferably 50 psi (345
kPa) or less, preferably 10 psi (69 kPa) or less. Alternately, in
any process described herein hydrogen, if present, is present in
the reactor and or feed at 1000 ppm or less by weight, preferably
750 ppm or less, preferably 500 ppm or less, preferably 250 ppm or
less, preferably 100 ppm or less, preferably 50 ppm or less,
preferably 25 ppm or less, preferably 10 ppm or less, preferably 5
ppm or less.
[0195] The reaction time or reactor residence time is usually
dependent on the type of catalsyt used, the amount of catalyst
used, and the desired conversion level. Different metallocenes have
diffferent activities. Usually, a higher degree of alkyl
substitution on the cyclopentadienyl ring, or bridging improves
catalyst productivity. Catalysts such as
bis(1,2,3,4-tetramethylcyclopentadienyl)zirconium dichloride or
bis(1,2,4-trimethylcyclopentadienyl)zirconium dichloride,
(1,2,3,4-tetramethylcyclopentadienyl)(1,3-di
methylcyclopentadienyl)zirconium dichloride or
(1,2,4-trimethylcyclopentadienyl)(1,3-di
methylcyclopentadienyl)zirconium dichloride or their dialkyl
analogs have desirable high productivity and stability than
unsubstituted metallocenes. Certain bridged and bridged with
substitution catalysts, such as the di-halides or dialkyls of
dimethylsilylbis[indenyl]zirconium or
dimethylsilylbis[tetrahydro-indenyl]zirconium
dimethylsilylbis[1-methylindenyl]zirconium or their hafnium
analogs, etc. Usually the amount of catalyst components used is
determinative. High amount of catalyst loading tends to gives high
conversion at short reaction time. However, high amount of catalyst
usage make the production process uneconomical and difficult to
manage the reaction heat or to control the reaction temperature.
Therefore, it is useful to choose a catalyst with maximum catalyst
productivity to minimize the amount of metallocene and the amount
of activators needed. When the catalyst system is metallocene plus
methylalumoxane, the range of methylalumoxane used is typically in
the range of 0.1 milligram (mg) to 500 mg/g of alpha-olefin feed. A
more preferred range is from 0.05 mg to 10 mg/g of alpha-olefin
feed. Furthermore, the molar ratios of the aluminum to metallocene
(Al/M molar ration) range from 2 to 4000, preferably 10 to 2000,
more preferably 50 to 1000, preferably 100 to 500. When the
catalyst system is metallocene plus a Lewis Acid or an ionic
promoter with NCA component, the metallocene use is typically in
the range of 0.01 microgram to 500 micrograms of metallocene
component/gram of alpha-olefin feed. Usually the preferred range is
from 0.1 microgram to 100 microgram of metallocene component per
gram of alpha-olefin feed. Furthermore, the molar ratio of the NCA
activator to metallocene is in the range from 0.1 to 10, preferably
0.5 to 5, preferably 0.5 to 3. If a co-activator of alkylaluminum
compound is used, the molar ratio of the Al to metallocene is in
the range from Ito 1000, preferably 2 to 500, preferably 4 to
400.
[0196] Typically one prefers to have the highest possible
conversion (close to 100%) of feed alpha-olefin in shortest
possible reaction time. However, in CSTR operation, sometimes it is
beneficial to run the reaction at an optimum conversion, which is
slightly less than 100% conversion. There are also occasions, when
partial conversion is more desirable when the narrowest possible
MWD of the product is desirable because partial conversion can
avoid a MWD broadening effect. If the reaction is conducted to less
than 100% conversion of the alpha-olefin, the unreacted starting
material after separation from other product and solvents/diluents
can be recycled to increase the total process efficiency.
[0197] Desirable residence times for any process described herein
are in the range from 1 minutes to 20 hours, typically 5 minutes to
10 hours. Each of these processes may also be employed in single
reactor, parallel or series reactor configurations. The liquid
processes comprise contacting olefin monomers with the above
described catalyst system in a suitable diluent or solvent and
allowing said monomers to react for a sufficient time to produce
the desired polymers or oligomers. Hydrocarbon solvents both
aliphatic and aromatic are suitable. Aromatics such as toluene,
xylenes, ethylbenzene, propylbenzene, cumene, t-butylbenzene are
suitable. Alkanes, such as hexane, heptane, pentane, isopentane,
and octane, Norpar or Isopar solvents from ExxonMobil Chemial
Company in Houston, Tex. are also suitable. Generally, toluene is
most suitable to dissove catalyst components. Norpar, Isopar
solvent or hexanes are preferred as reaction diluents. Oftentimes,
a mixture of toluene and Norpar or Isopar is used as diluent or
solvent.
[0198] The process can be carried out in a continuous stirred tank
reactor, batch reactor, or plug flow reactor, or more than one
reactor operated in series or parallel. These reactors may have or
may not have internal cooling and the monomer feed may or may not
be refrigerated. See the general disclosure of U.S. Pat. No.
5,705,577 for general process conditions.
[0199] When a solid supported catalyst is used for the conversion,
a slurry polymerization/oligomerization process generally operates
in the similar temperature, pressure and residence time range as
described previously. In a slurry polymerization or
oligomerization, a suspension of solid catalyst, promoters, monomer
and comonomers are added. The suspension including diluent is
intermittently or continuously removed from the reactor. The
catalyst is then separated from the product by filtration,
centrifuge or settlement. The fluid is then distilled to remove
solvent, any unreacted components and light product. A portion or
all of the solvent and unreacted component or light components can
be recycled for reuse.
[0200] If the catalyst used is un-supported, is a solution
catalyst, when the reaction is complete (such as in a batch mode),
or when the product is withdrawn from the reactor (such as in a
CSTR), the product may still contain soluble, suspended or mixed
catalyst components. These components are preferably deactivated or
removed. Any of the usual catalyst deactivation methods or aqueous
wash methods can be used to remove the catalyst component.
Typically, the reaction is deactivated by addition of
stoichiometric amount or excess of air, moisture, alcohol,
isopropanol, etc. The mixture is then washed with dilute sodium
hydroxide or with water to remove catalyst components. The residual
organic layer is then subjected to distillation to remove solvent,
which can be recycled for reuse. The distillation can further
remove any light reaction product from C18 and less. These light
components can be used as diluent for further reaction. Or they can
be used as olefinic raw material for other chemical synthesis, as
these light olefin product have vinylidene unsaturation, most
suitable for further functionalization to convert in high
performance fluids. Or these light olefin products can be
hydrogenated to be used as high quality paraffinic solvents.
[0201] Polymerization or oligomerization in absence of hydrogen is
also advantageous to provide polymers or oligomers with high degree
of unsaturated double bondss. These double bonds can be easily
converted into functionalized fluids with multiple performance
features. Examples for converting these polymers with MW greater
than 300 can be found in preparation of ashless dispersants, by
reacting the polymers with maleic anhydride to give PAO-succinic
anhydride which can then reacted with amines, alcohols, polyether
alcohols to convert into dispersants. Examples for such conversion
can be found in the book "Lubricant Additives: Chemistry and
Application," ed. By Leslie R. Rudnick, p. 143-170.
[0202] In another embodiment, any of polyalphaolefins produced
herein is hydrogenated. In particular the polyalpha-olefin is
preferably treated to reduce heteroatom containing compounds to
less than 600 ppm, and then contacted with hydrogen and a
hydrogenation catalyst to produce a polyalpha-olefin having a
bromine number less than 1.8. In a preferred embodiment, the
treated polyalpha-olefin comprises 100 ppm of heteroatom containing
compounds or less, preferably 10 ppm of heteroatom containing
compounds or less. (A heteroatom containing compound is a compound
containing at least one atom other than carbon and hydrogen.)
Preferably the hydrogenation catalyst is selected from the group
consisting of supported Group 7, 8, 9, and 10 metals, preferably
the hydrogenation catalyst selected from the group consisting of
one or more of Ni, Pd, Pt, Co, Rh, Fe, Ru, Os, Cr, Mo, and W,
supported on silica, alumina, clay, titania, zirconia, or mixed
metal oxide supports. A preferred hydrogenation catalsyt is nickel
supported on kieselguhr, or platinum or palladium supported on
alumina, or cobalt-molydenum supported on alumina. Usually, a high
nickel content catalyst, such as 60% Ni on Keiselguhr catalyst is
used, or a supported catalyst with high amount of Co--Mo loading.
Alternately, the hydrogenation catalyst is nickel supported on
keisleghur, silica, alumina, clay or silica-alumina.
[0203] In a preferred embodiment the polyalpha-olefin is contacted
with hydrogen and a hydrogenation catalyst at a temperature from 25
to 350.degree. C., preferably 100 to 300.degree. C. In another
preferred embodiment the polyalpha-olefin is contacted with
hydrogen and a hydrogenation catalyst for a time period from 5
minutes to 100 hours, preferably from 5 minutes to 24 hours. In
another preferred embodiment the polyalpha-olefin is contacted with
hydrogen and a hydrogenation catalyst at a hydrogen pressure of
from 25 psi to 2500 psi, preferably from 100 to 2000 psi. In
another preferred embodiment the hydrogenation process reduces the
number of mm triad groups in a polyalpha-olefin by 1 to 80%.
Prefeably the PAO has 10 to 80% less mm triad groups than the
polyalpha-olefin prior to contact with the hydrogen and
hydrogenation catalyst. For further infomration on hydrogenation of
PAO's please see U.S. Pat. No. 5,573,657 and "Lubricant Base Oil
Hydrogen Refining Processes" (page 119 to 152 of Lubricant Base Oil
and Wax Processing, by Avilino Sequeira, Jr., Marcel Dekker, Inc.,
NY, 1994.
[0204] This hydrogenation process can be accomplished in a slurry
reactor in a batch operation or in a continuous stirred tank
reactor (CSTR), where the catalyst in 0.001 wt % to 20 wt % of the
PAO feed or preferably 0.01 to 10 wt %, hydrogen and the
polyalpha-olefins are continuously added to the reactor to allow
for certain residence time, usually 5 minutes to 10 hours to allow
complete hydrogenation of the unsaturated olefins and to allow
proper conversion of the mm diads. The amount of catalyst added is
usually very small just to compensate for the catalyst
deactivation. The catalyst and hydrogenated PAO are continuously
withdrawn from the reactor. The product mixture was then filtered,
centrifuged or settled to remove the solid hydrogenation catalyst.
The catalyst can be regenerated and reused. The hydrogenated PAO
can be used as is or further distilled or fractionated to the right
component if necessary. In some cases, when the hydrogenation
catalyst show no catalyst deactivation over long term operation,
the stir tank hydrogenation process can be carried out in a manner
where a fixed amount of catalyst is maintained in the reactor,
usually 0.1 wt % to 10% of the total reactant, and only hydrogen
and PAO feed are continuously added at certain feed rate and only
hydrogenated PAO was withdrawn from the reactor.
[0205] The hydrogenation process can also be accomplished by a
fixed bed process, in which the solid catalyst is packed inside a
tubular reactor and heated to reactor temperature. Hydrogen and PAO
feed can be fed through the reactor simultaneously from the top or
bottom or countercurrently to maximize the contact between
hydrogen, PAO and catalyst and to allow best heat management. The
feed rate of the PAO and hydrogen are adjusted to give proper
residence to allow complete hydrogenation of the unsaturated
olefins in the feed and to allow desirable conversion of mm triads
in the process. The hydrogenated PAO fluid can be used as is or
further distilled or fractionated to give the right component, if
necessary. Usually, the finished hydrocarbon PAO fluids have
bromine number less than 2 and have reduced amount of mm triads
than the unhydrogenated PAO.
[0206] The new poly-alpha-olefins when used alone or blended with
other fluid has unique lubrication properties.
[0207] In another embodiment, a novel lubricatant of the present
invention comprises the PAO's produced in this invention, together
with one or more other base stocks, including Group I to Group V
base stocks with viscosity range from 1.5 to 100 cSt at 100.degree.
C. to formulate suitable viscosity grades. In addition, additives
of one or more of: thickeners, VI improvers, antioxidants,
anti-wear additives, detergent/dispersant/inhibitor (DDI) packages,
and/or anti-rust additives may be added. In a preferred embodiment
the PAO's produced herein are combined with one or more of
dispersants, detergents, friction modifiers, traction improving
additives, demulsifiers, defoamants, chromophores (dyes), and/or
haze inhibitors. These fully formulated lubricants can be used in
automotive crank case oil (engine oil), industrial oil, grease, or
gas turbine engine oil. These are examples of additives used in
finished lubricant formulations. Additional information on the use
of PAO's in the formulations of full synthetic, semi-synthetic or
part synthetic lubricant or functional fluids can be found in
"Synthetic Lubricants and High-Performance Functional Fluids", 2nd
Ed. L. Rudnick, etc. Marcel Dekker, Inc., N.Y. (1999). Additional
information on additives used in product formulation can be found
in "Lubricants and Lubrications, Ed. By T. Mang and W. Dresel, by
Wiley-VCH GmbH, Weinheim 2001.
EXAMPLES
[0208] The following examples are for purposes of illustration only
and are non-limiting examples.
[0209] The 1-decene used for all of the experiments was purified by
mixing 1 liter of untreated raw material with 20 grams of activated
13.times. molecular sieve, (which was activated by calcining at
200.degree. C. for at least four hours under a stream of purging
dry nitrogen gas), and 10 grams of Oxi-Clear catalyst (purchased
from Altech Associates, Inc of Deerfield, Ill. 60115) for at least
two days inside a glove box under a dry, inert atmosphere of
nitrogen. The molecular sieve and de-oxygenation catalyst were then
removed by filtration in the glove box to provide purified
1-decene. Alternatively, the feeds were purified by passing through
a bed of activated 13.times. molecular sieve alone under nitrogen
atmosphere.
[0210] The polymerization/oligomerization reaction was carried out
under nitrogen (N.sub.2) inert atmosphere or argon inert
atmosphere. In a small scale screening experiment, 2.2 grams of
purified 1-decene was added into a small stainless steel reactor
fitted with glass liner with a total reactor volume of 5.5 ml, an
agitator and a temperature controller, followed by addition of
0.668 ml of methylalumoxane (MAO) in toluene solution which was
prepared by diluting 10 wt % MAO in toluene solution to a dilute
solution containing 8.68 mg methylauminoxane per ml of solution
volume. The reactor was then heated to the desired reaction
temperature and the desired amount of metallocene catalyst in
toluene was added to initiate the polymerization reaction. After 3
hours, the reaction was quenched by addition of carbon dioxide
(CO.sub.2) gas of equal moles as the metallocene catalyst. The
polymerization/oligomerization product was isolated by stripping
the reactor contents, from about room temperature to 50.degree. C.,
under high vacuum for at least 2 hours to remove solvent, unreacted
starting material and dimer, i.e., any component having less than
thirty carbon atoms. The product properties, including molecular
weight and Mw/Mn, were analyzed by gel permeation chromatography
using tetrahydrofuran as the solvent and polystyrene as the
calibration standard. The residual fluid viscosity was calculated
by a correlation equation, which correlated the Mw by GPC to fluid
viscosity. The correlation equation used was:
Kv@100.degree. C. in
cSt=0.13+0.005578*Mw+1.37*.sup.10-6*(Mw).sup.2
[0211] Catalyst productivity was calculated as grams of product,
which is usually the C30 and higher component when 1-decene is used
as feed, per gram of MAO. In the case when an NCA was used as
co-catalyst, the catalyst productivity was calculated in gram of
product (C30 and higher) per gram of metallocene catalyst (not
including the NCA or co-activator).
[0212] Examples 1 through 10 were conducted generally as described
above, with additional experimental details provided in Table 1
below.
TABLE-US-00003 TABLE 1 Reactions were carried out using 0.1
micromole metallocene catalyst, Al/Zr molar ratio = 1000 Example
number 1 2 3 4 5 6 7 8 9 10 catalyst type* A B C D E F G E F G
reaction temperature, .degree. C. 100 100 100 100 100 100 100 50 50
50 product yield, wt % 65 65 71 29 88 76 29 88 41 94 g product/g
MAO 190 190 207 86 259 224 86 259 121 276 Mw g/mol 507 514 791 493
5860 1436 23935 12300 8280 27560 Mw/Mn 1.1 1.1 1.2 1.1 1.8 1.4 1.5
1.8 2 2 estimated 100.degree. C. vis, cSt** 3.3 3.4 5.4 3.2 80 11
918 276 140 1194 Reactions were carried out using 0.1 micromole
catalyst, Al/Zr molar ratio = 1000. *Catalyst type A
biscyclopentadienylzirconium dichloride B
dimethylsilylbis(cyclopentadienyl)zirconium dichloride C
bis(1,3-dimethylcyclopentadienyl)zirconium dichloride D
iso-propylidenebis(cyclopentadienyl)zirconium dichloride E
rac-ethylenebis(1-indenyl)zirconium dichloride F
rac-dimethylsilylbis(tetrahydroindenyl)zirconium dichloride G
diphenylmethylidene(cylcopentadienyl)(9-fluorenyl)zirconium
dichloride **Viscosity was calculated based on Mw determined by GPC
using the formula: Kv@100.degree. C. in cSt = 0.13 + 0.005578 * Mw
+ 1.37 * .sup.10-6 * (Mw).sup.2
[0213] Examples 11 through 17 were conducted generally as described
above, with additional experimental details provided in Table 2
below.
TABLE-US-00004 TABLE 2 Reactions were carried out at 100.degree.
C., using 0.1 micromole metallocene catalyst, Al/Zr molar ratio =
250 Example number 11 12 13 14 15 16 17 Catalyst type* H I J K C L
B product yield, wt %*** 21.7 28.3 15.9 17.3 38.1 23.2 27.6 g
product/g MAO 329 430 241 262 578 352 419 Mw (g/mol) 1715 1674 1807
1862 2305 2333 2331 Mw/Mn 1.1 1.1 1.1 1.1 1.2 1.2 1.2 Estimated
100.degree. C. vis, cSt** 4.0 3.8 4.4 4.7 6.7 6.9 6.9 Catalyst type
H bis(methylcyclopentadienyl)zirconium dichloride I
bis(ethylcyclopentadienyl)zirconium dichloride J
bis(n-butylcyclopentadienyl)zirconium dichloride K
bis(n-dodecylcyclopentadienyl)zirconium dichloride L
(methylcyclopentadienyl)(propylcyclopentadienyl)zirconium
dichloride **Viscosity was calculated based on Mw determined by GPC
using the formula: Kv@100.degree. C. in cSt = 0.13 + 0.005578 * Mw
+ 1.37 * .sup.10-6 * (Mw).sup.2 ***product yield weight % = 100
(residual weight/feed 1-decene weight) Examples 18 through 26 were
conducted generally as described above, with additional
experimental details provided in Table 3 below.
TABLE-US-00005 TABLE 3 Reactions were carried out at 100.degree.
C., using 0.1 micromole metallocene catalyst, Al/Zr molar ratio =
250 Sample number. 18 19 20 21 22 23 24 25 26 Catalyst type* M N O
P F G Q R S product yield, wt % 28.5 20.6 52.3 5.5 61.9 11.3 27.4
3.2 5.1 g polymer/g MAO 433 313 793 83 939 172 415 48 77 Mw 11287
11259 19822 10214 24369 298921 15278 14431 37372 Mw/Mn 1.1 1.1 1.3
1.1 1.3 1.8 1.2 1.2 1.9 Estimated 100.degree. C. 90 90 243 76 353
44524 153 138 781 viscosity, cSt** Catalyst type: M
bis(indenyl)zirconium dichloride N
cyclopentadienyl(indenyl)zirconium dichloride O
bis(1,2,4-trimethylcyclopentadienyl)zirconium dichloride P
bis(pentamethylcyclopentadienyl)zirconium dichloride Q
bis(1-methyl-3-n-propylcyclopentadienyl)zirconium dichloride R
bis(cyclopentadienyl)hafnium dichloride S bis(indenyl)hafnium
dichloride **Viscosity was calculated based on Mw determined by GPC
using the formula: Kv@100.degree. C. in cSt = 0.13 + 0.005578 * Mw
+ 1.37 * .sup.10-6 * (Mw).sup.2 ***product yield weight % = 100
(residual weight/feed 1-decene weight)
[0214] Example 27 to 32. In this set of experiments, the reaction
was carried out by adding 180 gram of purified 1-decene and a
catalyst solution, prepared by dissolving 2.017 millimole
methylalumoxane (1.17 gram of a 10 wt % in toluene solution) and
8.07 micromole of metallocene catalyst in 58 gram of toluene
solvent, into a 500 ml round bottom flask containing 180 gram
purified 1-decene heated to reaction temperature and equipped with
stirrer and temperature controller. The reaction mixture was
maintained at proper reaction temperature. After 4-10 hours, the
reaction was quenched by addition of 3-ml isopropanol, dilute HCl
solution and washed with 5% NaOH solution. The organic layer was
separated and distilled under full vacuum to remove any C20 and
lower components. The C30 and higher components were then
hydrogenated under typical hydrogenation conditions using Nickel on
Kieselguhr catalyst at 200.degree. C., 800 psi hydrogen for 4-8
hours. After hydrogenation, the bromine number of the samples were
below 1. The composition of the product was then analyzed by gas
chromatograph equipped with a 60 meter DB1 column (initial
temperature, 70.degree. C./0 minute, 10.degree. C./minute to
320.degree. C.). A typical gas chromatograph for the
C.sub.30H.sub.62 componentof example 31 is shown in FIG. 4. The
major components A and B were determined by comparison of the GC
retention time to the known compounds. Component A is believed to
be produced by hydrogenation of the olefin A'' produced from simple
1,2-connections of each 1-decene molecule. Component B is believed
to be produced by hydrogenation of olefin B'' produced from a
1,1-connection during the chain termination process. The presence
of component B is unexpected from this type of chemistry.
[0215] The amount of Component B, 1,1-octyldocosane, is related to
product viscosity, as demonstrated in Table 4. In Table 4, the
higher the lube viscosity, the higher the amount of component B is
in the 1-decene-trimer fraction. This is quite unexpected from
previously known chemistry. The presence of B is beneficial for
fluid property. For example, a C.sub.30H.sub.62 B compound,
synthesized independently from n-dodecyl aldehyde following a
well-defined chemical reaction path as shown in FIG. 5 (final
product B C.sub.30H.sub.62, 11-octyldocosane), has superior
viscometrics and VI (Kv at 100.degree. C.=3.38 cSt, VI=149), as
compared to the current low vis PAO of Kv at 100.degree. C.=4.1 cSt
and VI=126 or the synthesized C.sub.30 A with Kv at 100.degree. C.
of 3.67 and VI=130.
TABLE-US-00006 TABLE 4 lube properties and amount of compound B in
C30 component Example no 27 28 29 30 31 32 catalyst type A B I F F
F Reaction 50 100 70 126 100 70 temp., .degree. C. Lube properties
KV100.degree. C., 8.14 10.29 13.81 15.86 37.56 126.27 cSt
KV40.degree. C., cSt 43.8 56.73 85.04 100.57 284.04 1132.63
Viscosity Index 162 172 167 169 183 218 pour point, .degree. C.
<-55 <-50 <-52 <-55 -48 -33 Bromine 27.0 21.5 20.2 17.5
11.1 5.6 number before hydrogenation Bromine 0 0 0 0.5 0 0 number
after hydrogenation Wt % B 3.6 4.9 4.9 8.4 11.3 14.6 component in
C.sub.30H.sub.62 fraction Catalsyt type: A
biscyclopentadienylzirconium dichloride B
dimethylsilylbis(cyclopentadienyl)zirconium dichloride I
bis(ethylcyclopentadienyl)zirconium dichloride F
rac-dimethylsilylbis(tetrahydroindenyl)zirconium dichloride
[0216] For high viscosity fluids, the quantitative presence of the
1,1-connection can be determined by the proton NMR of the olefinic
region before hydrogenation. The olefinic carbons in component A''
and B'' have very different chemical shifts (FIG. 6). In the
olefinic region, each olefin class resonates in a characteristic
region assigned according to the table below:
TABLE-US-00007 Chemical shift Number of Olefin type range (ppm)
protons Vinyl 5.7-5.9 1 4.8-5.3 2 1,2-disubstituted 5.3-5.6 2
Trisubstituted 4.8-5.3 1 Vinylidene (1,1-disubstituted) 4.6-4.8
2
[0217] The total olefinic integral can be subdivided as described,
and gives quantitative concentrations for each olefin type.
[0218] Examples 33 to 35. Three poly- 1-decene samples were
prepared using similar procedures as Example 31, except at
different temperatures and the products were analyzed by proton NMR
before hydrogenation. The olefin distribution was determined as
described above, and a typical olefinic region of a proton NMR
spectrum is shown in FIG. 6. From this proton NMR analysis, we
calculated the mole % unhydrogenated B in total PAO product. After
hydrogenation, the B'' will be converted to B component. The B
component varied with the product viscosities and higher viscosity
fluid had higher amount of component B in the end group (Table
5).
TABLE-US-00008 TABLE 5 Amount of structure B'' in poly-1-decene
lube fluid by H-NMR Example no. 33 34 35 Catalyst F F F Reaction
temp., .degree. C. 100 70 45 KV100.degree. C., cSt 35.13 150.39
497.01 KV40.degree. C., cSt 254.27 1374.27 5174.28 Viscosity Index
187 224 278 Pour point, .degree. C. -44 -30 -22 Bromine No. before
11.1 4.8 2.3 hydrogenation Mole % of component by H-NMR A'' 78.9
66.2 41.2 B'' 15.9 30.0 53.9 Others* 5.2 3.8 4.9
[0219] The product made in Example 32 was evaluated for EHL
(elastohydrodynamic lubrication) traction performance using a
Mini-Traction Machine (MTM) from PCS Instruments Ltd. This device
uses a ball-on-plate configuration in which each is driven
independently in order to vary sliding and rolling speeds. Under
the varied sliding and rolling speeds, an EHL contact is formed
between the ball and plate thereby separating the surfaces. The
separated surfaces allow the lubricant shear effects to be
measured, while temperature and contact pressure are varied to
produce a comprehensive map of the fluid's behavior. As referenced
in FIG. 7, the traction coefficient is a ratio of the EHL traction
force measured to the normal force applied (F.sub.t/F.sub.n). The
results are presented in Table I.
TABLE-US-00009 TABLE I Pressure (GPa) 0.75 1 1.25 At 80.degree. C.
SpectraSyn 100 0.0151 0.0246 0.0308 SpectraSyn Ultra 150 0.013
0.0227 0.0299 Hydrogenated Example 32 PAO 0.0123 0.0222 0.0291 at
100.degree. C. SpectraSyn 100 0.0118 0.0201 0.0263 SpectraSyn Ultra
150 0.0111 0.0191 0.0256 Hydrogenated Example 32 PAO 0.0106 0.0187
0.025 At 120.degree. C. SpectraSyn 100 0.0088 0.0149 0.0205
SpectraSyn Ultra 150 0.0084 0.0143 0.02 Hydrogenated Example 32 PAO
0.0072 0.0129 0.0186
[0220] FIG. 7 compares the traction coefficients of conventional
PAO with 100 cSt viscosity (at 100.degree. C.), SpectraSyn.TM. 100,
a SpectraSyn Ultra.TM. 150 and hydrogenated polyolefin of Example
32. As the data show, hydrogenated Example 32 lube has a
consistently lower traction coefficient over a wide range of test
pressure and temperature Lower traction coefficient is more
desirable and is advantageous for energy efficiency
(Reference--Synthetic Basics, Benefits of Synthetic Lubricants in
Industrial Applications, W. R. Murphy, D. A. Blain, A. S.
Galiano-Roth, J. Synthetic Lubrication, January 2002 (18) p.
301).
[0221] Examples 36 to 41. This set of experiments was carried out
in a continuous reactor. These runs demonstrated the use of
non-cordinating anion (NCA) as activiator, high lube yields and or
narrow molecular weight distribution. 1-Decene and toluene used in
the runs were purified through a SAngstrom molecular sieve. The
metallocene catalyst used was
dimethylsilylbis[tetrahydroindenyl]zircornium dimethyl. The
activator used was N,N-dimethylanilinium
tetra(pentafluorophenyl)borate (labled as activator-A or NCA-A). A
catalyst solution was prepared by pre-mixing equal molar of
metallocene with the activator in toluene solution to give 0.8
micromole catalyst per ml of solution. The experiments were
conducted in a series dual-reactor continuous solution process.
Both of the reactors were 1-liter autoclave reactors. All feeds
were introduced into the first reactor. Both of the reactors were
controlled at the same reaction temperature. The catalyst solution
of 0.8 micromole/ml, a scanveger tri-n-octylaluminum (TNOA)
solution, and purified 1-decene were continuously pumped into an
one-liter stainless autoclave heated to reaction temperature.
Reaction product was continuously withdrawn from the autoclave,
quenched, and washed with water. The organic layer was further
distilled at high temperature to remove any C20 and lighter
components. These data demonstrated that the NCA activator gave
excellent catalyst productivities, conversions and or lube yields.
The residual oil was then hydrogenated using 1 wt %
Ni-on-Kieselguhr catalyst at 200.degree. C., 800 psi (5.5 MPa)
hydrogen pressure for 4 hours. The bromine numbers for all samples
after hydrogenation were much below 1. The reaction conditions and
the hydrogenated finished lube properties are summarized in the
following Table 6. This set of data demonstrates that a wide range
of viscosities can be produced at high productivities. Also, these
data show that a wide range of mm contents, ranging from 86% to
51%, can be produced.
[0222] Carbon-13 NMR was used to determine the tacticity of the
polyalphaolefins of the present invention. Carbon-13 NMR can
determine the presence and quantity of triads present, denoted mm
(meso, meso), mr (meso, racemic) and rr (racemic, racemic).
Extensive runs of mm or rr triads correspond to isotactic and
syndiotactic polyalphaolefins, respectively. The tacticity of the
polydecene was examined by carbon-13 NMR. Spectra for these samples
were acquired in the following manner. The polymer samples were
dissolved in chloroform-d for carbon analysis. Approximately 10-15
mg/ml of chromium acetylacetonate relaxation agent, Cr(acac).sub.3,
was added to the carbon samples to enhance the data acquisition
rate. Spectra were acquired using the 10 mm broadband probe on
either the Varian INOVA 300 or the Varian UnityPlus 500, with
8000-12000 scans acquired for each spectrum. Three carbon chemical
shifts in polydecene and polydodecene evidence tacticity
dependence: the S.sub..alpha..alpha. backbone methylene, and the
8B.sub.8 and 7B.sub.8 methylenes (for decene) and the 10B.sub.10
and 9B.sub.10 methylenes (for dodecene) on the short chain branches
(SCBs). A peak deconvolution was performed on the 8B.sub.8 or
10B.sub.10 peaks, and assigned to monomer stereochemical triads
according to the paper by I. Kim, J.-M. Zhou, and H. Chung, Journal
of Polymer Science: Part A: Polymer Chemistry 38 (2000) 1687-1697.
FIG. 3 in the paper by Kim, et al. shows how the chemical shift
offset of the relevant branch methylene varies with branch length.
Based on the trends shown, we assumed that the dodecene- and
decene-based SCBs were both of sufficient length that the chemical
shift assignments for the 8B.sub.8 and 10B.sub.10 methylenes would
be interchangeable. It also follows from this figure, that
copolymers of different alphaolefins will have spectra complicated
by monomer sequence effects. Furthermore, several of the samples
are low M. materials, and contributions from chain end carbons
overlap the region of interest. Where possible, the end group
resonances were identified, integrated. Their contribution to the
peaks were removed from the analysis. The deconvolutions were
executed with Acorn NMR Inc.'s NutsPro NMR data analysis software,
using an 85/15 Lorentzian/Gaussian lineshape. The component peaks
were lumped together into clusters according to the mm
(.about.34.65-35.4 ppm), mr (.about.34.2-34.65 ppm), and rr
(33.8-34.2 ppm) triad assignments, and fit by least-squares
minimization to a Bernoullian distribution. The probability of
racemic addition, P.sub.r, is the adjustable parameter. The exact
chemical shift offset cut points for the stereo triad regions may
vary somewhat as a function of solvent type, temperature, sample
concentration, and relaxation agent concentration. A typical
spectrum of this region was shown in FIG. 8.
[0223] End group-related resonances appear in the 42-45 ppm and
35-36.5 ppm regions. Visual inspection of low-Mn materials suggests
that there are three endgroup carbons contributing to the 8B.sub.8
or 10B.sub.10 region, with one carbon in each of the mm, mr, and rr
triad regions. As a first-order approximation to end group
correction, the end group resonances (where detected) in the 42-45
and 35-36.5 ppm regions were integrated by deconvolution. The
integral values so obtained were averaged and subtracted from each
of the mm, mr, and rr triad areas. In general, the quality of fit
improves upon such correction. The carbon-13 data is reported in
Table 6 and is reported in mole %.
[0224] Branch concentrations were also determined by NMR
spectroscopy. The characteristic shift ranges for the carbon
spectra are methyl branch: 20-15 ppm, propyl branch: 15-14.2 ppm,
butyl and longer branches: 14.2-13 ppm, ethyl branches: 12-8 ppm.
In the proton spectra, the methyl protons resonate upheld of 1 ppm,
and signals from different branch lengths can often be resolved
sufficiently to allow quantification by branch length. A typical
spectrum of this region was shown in FIG. 9. In the carbon spectra,
the integrals of the branch methyl signals can be divided by the
total spectral integral, and the result expressed in terms of
branches per 1000 carbons. The same holds true for the proton
spectrum, although the integrals need to be corrected for the
proton multiplicity of the relevant carbon (e.g. CH, CH.sub.2, or
CH.sub.3). FIG. 9 shows the methyl region of a decene carbon
spectrum.
TABLE-US-00010 TABLE 6 Reaction Conditions for Ex 36 to 41 Ex. No
36 37 38 39 40 41 Rxr Tem. (.degree. C.) 50 60 70 80 90 100
1-decene (ml/min) 40 40 40 40 40 40 Cat rate (mol/min) 2.39E-06
2.39E-06 3.73E-06 3.73E-06 3.73E-06 3.73E-06 TNOA (mol/min)
7.57E-10 7.57E-10 9.10E-10 9.10E-10 9.10E-10 9.10E-10 Yield (g/min)
21.9 24.14 25.43 28.04 29.19 na Conversion, wt % 73.27 80.76 85.08
93.84 97.67 na Productivity g-lube/g 2.19E+04 2.41E+04 1.63E+04
1.80E+04 1.87E+04 na cat. KV at 100.degree. C., cSt 295.21 169.07
79.49 26.54 14.89 11.2 KV at 40.degree. C., cSt 3002.3 1618 696.8
197.2 99.7 70.4 Viscosity Index 249 225 197 169 155 150 Pour point,
.degree. C. -30 -30 -33 -48 -52 -57 Bromine number 0.09 0.05 0.00
0.00 0.05 0.22 after hydrogenation Mw 10732 7579 4823 2586 1760
1493 Mw/Mn 1.758 1.671 1.516 1.317 1.161 1.14 Tacticity by C13 NMR,
in mole % mm 86 86 76 69 62 51 mr 13 14 22 28 33 41 rr 1 0.1 2 3 1
8 Pr 0.07 0.07 0.13 0.17 0.21 0.29 Ratio of mm/mr 6.6 6.1 3.5 2.5
1.9 1.2 CH3 per 1000 Carbons Measured by C13-NMR 1.9 2.7 3.9 8.1
13.0 16.2
[0225] The Example 36 and Example 37 products were subjected to a
tapered roller bearing shear test (CEC L-45-T/C), a severe
viscosity shear stability test, for 20 hours. At the end of the
test, the Example 36 fluid lost only 0.77% of its original
viscosity. The Example 37 fluid lost -0.20% of its original
viscosity. This viscosity change is well within the experimental
error of viscosity measurement. Such outstanding shear is not known
for other fluids of similar viscosity range. This property can be
significant for many high performance application, such as in the
formulation of automotive engine, industrial, gear oils and grease
formulation, etc.
[0226] Example 42 demonstrates the use of the dihalide form of a
metallocene catalyst with an NCA activator. The metallocene used
was catalyst F. A reaction flask containing containing 50 gram
purified 1-decene and 31.74 mg tri-siobutylaluminum (TIBA) was
heated to 30.degree. C. To this flask a catalyst solution
containing 0.912 mg F catalyst and 0.801 mg activator-A in 20 ml
toluene was added. After 20 hours of reaction at this temperature,
2 ml isopropanol was added. The reaction mixture was worked up by
water wash. The product was distilled at 160.degree. C./1 mm-Hg
vacuum to remove any light ends. The residual lube oil properties
are summarized in Table 7. Examples 43 to 46 are similar to Example
42 except at different reaction temperature. Example 47 is similar
to Examples 42, except catalyst I was the metallocene used.
TABLE-US-00011 TABLE 7 1-Decene polymerization by metallocene and
NCA activator-A Example No. 42 43 44 45 46 47 Reaction Temp, C.
30-40 30-65 70 120 140 70 Solution weight in reactor 1-decene,
grams 50 50 50 50 50 50 TIBA, mg 31.74 63.6 63.6 63.6 63.6 63.6
Toluene, grams 0 0 20 20 20 20 Metallocene, mg 0.912 0.912 0.954
0.918 0.912 0.697 NCA-A activator, mg 0.801 3.205 3.205 3.205 3.205
3.205 wt % Selectivity to Lube 95.7 97.0 96.2 80.6 73.0 94.0 KV at
100.degree. C., cSt 1095.2 194.61 72.53 8.43 6.2 40.08 Viscosity
Index 310 226 191 151 145 167 Pour Point, .degree. C. -28 -38
<-56 Mw 25151 9094 4718 1358 Mw/Mn 2.05 2.04 1.62 1.22
These Examples 42 to 46 demonstrate that high quality lube can be
produced in high yields. The lubes have high VI and very narrow
Mw/Mn. Also, high selectivity to lube can be obtained with these
catalysts. For Example 48 and 49 in Table 8, the metallocene was
catalyst F. For Example 50 in Table 8 the metallocene was catalyst
I.
TABLE-US-00012 TABLE 8 1-Decene reaction over metallocene and
activator-B as activator Example No. 48 49 50 Reaction Temp, C. 70
140 70 Solution weight in reactor 1-decene, grams 50 50 50 TIBA, mg
65 65 65 Toluene, grams 20 20 20 Metallocene, mg 0.456 0.456 0.348
NCA activator, mg 0.922 0.922 0.922 wt % Selectivity to Lube 99.4
69.1 93.6 Kinematic Viscosity at 100.degree. C., cSt 83.71 6.76
39.03 Viscosity Index 194 162 170
[0227] Examples 51 to 63 in Table 9 demonstrate that other
metallocene catalysts activated with MAO or NCA activators can
produce high quality fluids in high yields. The procedures for
these examples were similar to Examples 27 to 32 when MAO was the
activator or similar to Example 42 when NCA was used as activator.
[Note--these samples were not hydrogenated.] Examples 51 to 56
demonstrate that a wide range of catalysts can be used to produce
polymers with high degree of mm triads. These catalysts include the
racemic catalysts including Catalysts F, E, and T; and highly
susbstituted catalyst U. Examples 59 to 62 demonstrate that using
meso type catalysts with no hydrogen produces fluids with lower
degree of mm triads (e.g. less than 40%) and bromine number of up
to 6 before hydrogenation. This is unexpected when compared to U.S.
Pat. No. 6,706,828.
TABLE-US-00013 TABLE 9 Polymer fluids from 1-decene by different
metallocene catalysts - reaction conditions, results, product
properties and tacticity analysis. % Pour Mole % analyzed by
C13-NMR Reaction Selectivity to KV@100.degree. C., point, Br. mm/mr
Ex. no. Catalyst* temp. .degree. C. lube cS VI .degree. C. No**. mm
mr rr Pr ratio 51 F 50 96 295.2 249 -30 2.8 87 5 9 0.05 17.4 52 E
50 100 1028.96 306 -19 0.8 98 2 0 0.01 49 53 E 75 94 368.05 252 na
0.5 83 16 1 0.09 5.1 54 E 100 74 92.61 200 -39 4.3 65 31 4 0.2 2.1
55 E 125 48 41.94 187 -50 10.5 64 32 4 0.2 2.0 56 M 70 95 32.05 170
na 10.2 42 46 13 0.36 3.2 57 T 70 88 3044.88 165 na na 88 12 4 0.06
7.3 58 U 70 99 101.67 193 -38 3.9 31 49 2 0.44 15.6 59 V 70 99
2339.93 354 na na 34 49 17 0.41 0.7 60 W*** 50 99 3758.42 380 na na
34 49 17 0.41 0.7 61 W 50 99 1383.62 323 -27 na 34 49 17 0.42 0.7
62 W 70 98 861.34 296 -30 na 33 49 18 0.43 0.7 63 W 125 76 117.72
206 -41 5.7 34 49 17 0.42 0.7 *Catalyst type T
Rac-dimethylsilylbis(2-methylindenyl)ZrCl2 U
Bis(tetramethylcyclopentadienyl)ZrCl2 V
meso-dimethylsilylbis(2-methylindenyl)ZrCl2 W
meso-ethylenebis(indenyl)ZrCl2 **The samples in this Table were not
hydrogenated and the Bromine numbers were measured before
hydrogenation. ***NCA activator A was used.
[0228] Examples 64 to 69 demonstrate the advantages of
hydrogenation of the polyalpha-olefins produced from the
polymerization step. In this hydrogenation reaction, the Example 52
polyalpha-olefin was charged into an autoclave together with 3 wt %
of a Ni (.about.60%) on Kieselguhr hydrogenation catalyst, purged
with hydrogen to remove air and pressurized with hydrogen to 800
psi (5.5 MPa) and heated to 250.degree. C. with agitation. The
sample was allowed to hydrogenated for different period of reaction
time. All the hydrogenated samples have bromine number less than
0.5. Other properties of the fluids are summarized in Table 10.
These data demonstrate that post-polymerization hydrogenation not
only reduces the bromine number to below 1, but also we can produce
polyalpha-olefins with 26 to 95 mole % of mm triads. Furthermore,
comparing the DSC of the hydrogenated samples versus the
unhydrogenated sample, the hydrogenated samples had reduced heat of
melting (.DELTA.Hm, j/g) and heat of crystallization (.DELTA.Hc,
j/g). Hydrogenation of the sample can reduce the heat of melting
and crystallization as shown in Table 10.
TABLE-US-00014 TABLE 10 Example No. 52 64 65 66 67 68 69 time, hrs
Starting 1 2 4 7 12 24 PAO Mole % diads by C13-NMR mm 98 95 72 57
45 36 26 mr 2 3 15 20 41 38 47 rr 0 3 13 22 14 27 26 Pr 0.01 0.02
0.13 0.21 0.33 0.43 0.5 Mole % mm 0 3 26 41 53 62 72 change DSC
.DELTA.Hm, j/g 25.01 22.69 21.58 13.98 2.051 0 0 .DELTA.Hc, j/g
19.94 21.38 15.68 18.13 1.683 0 0 % Hm decrease 0.0 9.3 13.7 44.1
91.8 100 100
[0229] DSC (Differential scanning calorimetry) was measured using a
Perkin Elmer DSC. 10 mg samples was heated at 10.degree. C./minutes
to 150.degree. C. and then cooled down to -100.degree. C. at
10.degree. C. per minute. The total heat of melting and
crystallization during cooling was measured by integrating the heat
corresponding to the melting and crystallization peak using the
standard software provided by Perkin Elmer.
[0230] Example 70 to 74 were carried out similarly to Ex. 31,
except 1-hexene was used in each experiment. The amounts of
catalyst and activators used, together with product properties are
summarized in Table 11. This set of examples demonstrated that
other alpha-olefins can be used to produce high quality fluids.
TABLE-US-00015 TABLE 11 Example 70 71 72 73 74 tempera- 45 70 100
125 170 ture, .degree. C. reaction 22 20 21 21 24 time, hr grams 91
90 90 90 90 hexene feed grams 0.117 0.0585 0.0585 0.0585 0.0585 of
MAO solution molar 300 250 250 250 250 ratio Al/Zr KV100.degree.
1535.53 564.63 75.09 24.3 8.64 C., cSt KV40.degree. 42368.3
12822.88 1086.46 253.28 59.27 C., cSt Viscosity 239 198 132 112 108
Index pour point, .degree. C. Wt % 93 92 88 87 na Conver- sion
[0231] Examples 75 to 78 in Table 12 are similar to Example 42 to
46, except 1-hexene was used as starting material. These
experiments demonstrated that 1-hexene can be polymerized into high
quality fluids using metallocene and NCA activators and
trialkylaluminum compounds as co-activator.
TABLE-US-00016 Example 75 76 77 78 Reaction Temperature, .degree.
C. 31 80 100 120 Conversion, wt % 89.4 93.5 86.5 49.1 Lube
Properties KV100.degree. C., cSt 269.21 53.57 25.78 12.02
KV40.degree. C., cSt 4900.26 661.38 269.58 96.66 Viscosity Index
176 132 115 105 Pour Point, .degree. C. -24 -40 -32 -43 Mn 2519
1613 1211 912 Mw/Mn 3.025 1.667 1.315 1.287 Mole % Olefin Types in
Unhydrogenated Polyalpha- Olefins Vinyledene 67.4 71.4 72.3 72.2
1,2-disubstituted 15.7 11.6 8.8 5 tri-substituted 16.9 17 18.9 22.8
vinyl 0 0 0 0
[0232] Using catalyst E (rac-ethylenebis(indenyl) ZrC12) at
different reaction temperature and similar reaction procedures, we
obtained products with useful 100.degree. C. viscosities ranging
from 42 cSt to 1029 cSt (Examples 79 to 82 of Table 13) without any
hydrogen.
TABLE-US-00017 TABLE 13 Pour Reaction Kv@100.degree. C.,
Kv@40.degree. C., point, Example no Temp., .degree. C. cS cS VI
.degree. C. mm mr rr Pr 79 50 1028.96 12399 306 -19 0.98 0.02 0
0.01 80 75 368.05 4009.3 252 na 0.83 0.16 0.01 0.09 81 100 92.61
842.29 200 -39 0.65 0.31 0.04 0.2 82 125 41.94 316.73 187 -50 0.64
0.32 0.04 0.2
[0233] The product composition produced in this invention is
different from the compositions produced in U.S. Pat. No. 6,706,828
and WO 02/14384. Our invention using metallocene catalysts with MAO
or NCA activator optionally with co-activators in low or no
hydrogen (usually less than 200 psi hydrogen preferably less than
50 psi or no hydrogen) during the polymerization step. In contrast,
U.S. Pat. No. 6,706,828 and WO 02/14384 produced products from meso
catalysts in the presence of hydrogen, as reported in Example D of
U.S. Pat. No. 6,706,828 or Example J and K in WO 021484. FIG. 1
compares the bromine number of polymers produced in our invention
vs Examples 1, 2, 8, 9, 10, 11, and 12 of U.S. Pat. No.
6,706,828.
[0234] In Comparative example 1, the reaction was conducted in the
presence of 200 psi hydrogen and catalyst T
(rac-dimethylsilylbis(2-methyl-1-lindenyl)zirconium dichloride,
similar to Example D of U.S. Pat. No. 6,706,828. The results are
summarized in Table 12. The polyalpha-olefin sample was analyzed
for the Z mole % of B components in C30 fraction. The amount of
this Z mole % was plotted in FIG. 2.
[0235] Comparative Examples 2 and 3 were similar to Comparative
Example 1, except the reaction hydrogen pressure was 100 and 50
psi. The polyalpha-olefin sample was then analyzed for the mole %
of B components in C30 fraction. Comparative Example 4 was similar
to Comparative Example 1, except the reaction was carried out at
110.degree. C.
TABLE-US-00018 TABLE 12 Comparative Examples using
rac-dimethylsilyl- bis(2-methylindenyl)zirconiumdichloride Compar-
Compar- Compar- Compar- ative ative ative ative Example 1 Example 2
Example 3 Example 4 Temperature, .degree. C. 100 100 100 110
Hydrogen pressure, psi 200 100 50 200 KV@100 C., cSt 89.5 466.2
598.01 59.10 % B in C30 fraction 5.7 4.3 2.2 7.5 CH.sub.3 per 1000
C by C13 14.2 2.7 2.5 na NMR Viscosity Index 194 266 281 Pour
Point, .degree. C. -36 -21 -21
[0236] The amount of B mole % for the Comparative Examples 1-4
versus the amount of B mole % by Examples 27 to 35 is plotted in
FIG. 2.
[0237] Also, the amount of isolated CH.sub.3 attached to a tertiary
CH was analyzed by Carbon 13 NMR method and are summarized in Table
12. FIG. 10 compares the amount of CH.sub.3 per 1000 Carbons of the
Comparative Examples 1 to 3 produced in the presence of hydrogen
during polymerization to the CH.sub.3 per 1000 Carbons of Examples
36 to 41 produced without hydrogen during polymerization. This
graph clearly shows that the compositions of Examples 36 to 41 have
much lower methyl groups per 1000 Carbons. A lower amount of methyl
groups is advantageous to the lube properties, as we have shown
earlier that the trimer C30H62 without extra methyl group (Compound
B) has better viscometrics, especially VI, than trimers in current
PAO which has extra short chain branches. Furthermore, less
CH.sub.3 branches imply less tertiary hydrogen in the hydrocarbon
structure. This tertiary hydrogen is more susceptible toward
oxidative degration. This implies that compositions with less
CH.sub.3 branches and less tertiary hydrogen are less susceptible
to oxidative degradation.
[0238] Table 13 shows that the types of unsaturation from
Comparative Example 4 are very different from the types of
unsaturations produced from Example 33 or 76. In Comparative
Example 4 which used 200 psi hydrogen, 52% of the unsaturated
double bonds were tri-substituted olefins. In contrast, in Example
33 or 76, where no hydrogen was added to the reactor, only 10 to
17% of the unsaturation double bonds are tri-substituted olefins by
either MAO or NCA as co-activator.
TABLE-US-00019 TABLE 13 Comparison of unsaturation types.
Comparative Example 4 Example 33 Example 76 KV at 100.degree. C.,
cSt 59.10 35.1 53.57 Mole % trisubstittued olefins 52 10 17.0 Mole
% vinylidene 41 71 71.4 Mole % 1,2-disubstituted 7 19 11.6
olefins
[0239] In preferred embodiments, the polyalpha-olefins produced
herein have higher bromine numbers, the amount of tri-substituted
olefins are significantly lower than prior art, and/or the amount
of vinylidene+1,2-disubstituted olefins are higher. In further
preferred embodiments the PAO's produced herein have higher amounts
of B'' structures believed to be formed from head-to-head
connection in the polymer product. 3. In further preferred
embodiments the PAO's produced herein have high mole % of mm
content (>40%). In further preferred embodiments the PAO's
produced herein have higher mole % of B'' formed by head-to-head
connection. This is indicated by the higher C30-B component by GC
or the un-expected higher mole % of the di-substituted olefins of
the B'' structure.
[0240] These structural differences for the polyalpha-olefins
persist after hydrogenation step(s) to remove the double bond, as
is usually practiced to further improve lube base stock property.
After hydrogenation, the examples above had lower amount of
isolated CH.sub.3 per 1000 carbons in the polymers than the
Comparative Examples, even when the same polymerization catalysts
were used. In our examples, we preferred to hydrogenate the sample
after the polymerization. During this hydrogentation step, a we can
tailor the mole % of mm content in the polymer. By selection of
hydrogenation condition, we can maintain the same mole % of mm
content or we can reduce the mole % mm content to significantly
below 40.
[0241] Examples 90, 91 and 92 illustrate the presence of a minor
amount of ethylene in the polymerization. The procedure, catalyst,
activator, and reaction conditions were the same as for Example 46,
except that ethylene was present.
TABLE-US-00020 Ex. No. 90 91 92 Polymerization temperature
(.degree. C.) 80 80 80 1-decene feed rate (ml/min) 40.00 40.00
40.00 Ethylene feed rate 0.18 0.01 0.35 (standard liter per minute)
Catalyst/activator combination feed 3.73E-06 2.39E-06 2.39E-06 rate
(mol/min) TNOA feed rate (mol/min) 9.10E-10 9.10E-10 9.10E-10 Yield
(g/min) 29.5 29.0 30.5 Conversion (%) 98 97 100 Productivity (g
lube/g catalyst) 1.89E+04 2.90E+04 3.05E+04 Mn (kg/mol) 1.15 1.52
1.57 Mw (kg/mol) 1.31 2.00 1.70 Mw/Mn 1.14 1.32 1.09 Wt % C2 in
feed 3.63 0.21 6.87 Kv at 100.degree. C., cSt 11.67 22.81 15.58 Kv
at 40.degree. C., cSt 69.94 150.44 101.19 viscosity index 151 166
153
[0242] All documents described herein are incorporated by reference
herein, including any priority documents and/or testing procedures,
except to the extent they are inconsistent with this specification.
As is apparent from the foregoing general description and the
specific embodiments, while forms of the invention have been
illustrated and described, various modifications can be made
without departing from the spirit and scope of the invention.
Accordingly, it is not intended that the invention be limited
thereby.
* * * * *